JP5957307B2 - Mold, resin molding and siding material manufacturing method - Google Patents

Description

  The present invention relates to a mold, and a resin molded body and a method for producing a siding material.

  As exterior decorative materials for outer walls of buildings and structures, for example, ceramic siding materials, metal siding materials, and synthetic resin siding materials are known. Ceramic siding materials are excellent in strength and coatability. However, ceramic siding materials are prone to cracking in cold regions because they are repeatedly expanded and contracted by freezing and thawing of water contained in concrete. Further, the metal siding material has a problem of rust due to salt damage. On the other hand, synthetic resin-based siding materials made of synthetic resin such as vinyl chloride resin are excellent in durability, resistant to rust due to salt damage, cracking due to repeated freezing and thawing, and excellent water repellency and impact resistance. In addition, it is lightweight and has good workability.

As a method for producing a resin molded body having a protruding portion such as a rib provided on a substrate, such as a synthetic resin siding material, an extrusion molding method is widely used (for example, Patent Documents 1 and 2). Specifically, for example, a method using extrusion molding using the mold 200 illustrated in FIGS.
The mold 200 has a resin flow path 210 in which a molten resin flows. The resin flow path 210 includes an introduction portion 212 into which the molten resin is introduced, and a resin molded product whose cross-sectional shape of the flow path is a target. The flow passage has an enlarged portion 214 that gradually increases in size so as to have a cross-sectional shape equivalent to the cross-sectional shape. The cross-sectional shape of the flow path and the cross-sectional shape of the resin molded body are cross-sectional shapes when the flow path and the resin molded body are cut along a plane perpendicular to the flow direction of the molten resin (MD direction), respectively.
The molten resin introduced into the introduction portion 212 of the resin flow path 210 in the mold 200 is shaped into a predetermined shape having a protruding portion such as a substrate and a rib in the enlarged portion 214 and is discharged from the discharge port 216. It becomes the target resin molding by cooling later.

Japanese Patent Laid-Open No. 10-25384 JP 11-138633 A

  However, in a method of manufacturing a resin molded body such as a synthetic resin-based siding material using a conventional mold such as the mold 200, a direction (TD direction) perpendicular to the MD direction in the resin molded body is used. Problems such as chipping may occur at the end, and it is difficult to stably mold a resin molded body having a predetermined shape.

  The present invention relates to a mold capable of stably molding a high-quality resin molded body having a substrate and a protruding portion projecting from the substrate, and a method for producing a resin molded body and a siding material using the mold. For the purpose of provision.

The mold of the present invention is a mold for extruding a resin molded body having a substrate and a projecting portion projecting from the substrate,
Having a resin flow path through which the molten resin flows,
The resin flow path, the introduction part into which the molten resin is introduced;
An enlarged portion in which the flow passage gradually increases in the TD direction from the introduction portion side so that the cross-sectional shape of the flow passage is larger than the cross-sectional shape of the resin molded body;
A reduced portion in which the flow path is gradually reduced from the enlarged portion side so that the cross-sectional shape of the flow path is equivalent to the cross-sectional shape of the resin molded body,
In the reduced portion side within the enlarged portion, the height of the flow path of both ends of the TD direction is higher than the height of the flow path of the central portion, the flow path towards the opposite end portions than the center portion becomes wider It is characterized by.

  The method for producing a resin molded body of the present invention is a method of manufacturing a resin molded body having a substrate and a protruding portion protruding from the substrate, and the resin molded body is formed by extrusion molding using a mold of the present invention. This is a method having a molding step of molding.

  The method for producing a siding material of the present invention is a method of producing a siding material having a substrate and a resin molded body having a projecting portion projecting from the substrate, wherein the resin is formed by extrusion molding using a mold of the present invention. It is a method having a molding step of molding a molded body.

The metal mold | die of this invention can shape | mold stably the resin molding which has a board | substrate and the protrusion part protrudingly provided by this board | substrate.
According to the method for producing a resin molded body of the present invention, a high-quality resin molded body having a substrate and a projecting portion projecting from the substrate can be obtained.
According to the method for producing a siding material of the present invention, a high quality siding material having a substrate and a resin molded body having a projecting portion projecting from the substrate can be obtained.

It is the perspective view which showed an example of the metal mold | die of this invention. It is a top view of the metal mold | die of FIG. It is AA sectional drawing of the metal mold | die of FIG. It is BB sectional drawing of the metal mold | die of FIG. It is a side view of the siding material manufactured using the metal mold | die of FIG. It is the front view which looked at the siding material of FIG. 5 from the surface side. It is the rear view which looked at the siding material of FIG. 5 from the back surface side. It is the perspective view which showed an example of the conventional metal mold | die. It is a top view of the metal mold | die of FIG.

<Siding material>
Hereinafter, the siding material 10 which is an example of the siding material manufactured using the metal mold | die of this invention is demonstrated based on FIGS.
The “siding material surface” is the surface on the outdoor side when the siding material is attached to the outer wall of the building, and the “back surface of the siding material” is the opposite side, that is, the surface on the building side. It is. In addition, “upper” at the upper edge, upper end, and the like of the siding material means a side that becomes an upper side when the siding material is attached to an outer wall of a building.

As shown in FIGS. 5 to 7, the siding material 10 includes a synthetic resin resin molded body 12 and a design layer 14 formed on the surface of the resin molded body 12. The resin molded body 12 includes a rectangular substrate 16, an upper projecting portion 18 projecting above the substrate 16, a lower projecting portion 20 projecting below the substrate 16, and the back side of the substrate 16. And two rear side projecting portions 22, 22 projecting from each other.
The upper projecting portion 18 includes an upper end surface portion 24 that extends perpendicularly from the upper end of the substrate 16 to the surface of the substrate 16 and on the opposite side of the design layer 14 side, and an upper end surface portion 24 that is opposite to the substrate 16 side. An upper edge 26 extending in parallel to the surface of the substrate 16 from the end and opposite to the substrate 16 side, and a protrusion protruding from the design layer 14 side on the upper surface of the upper end surface portion 24 to the side opposite to the substrate 16 side. It consists of Article 28. The lower protruding portion 20 protrudes perpendicularly from the vicinity of the lower end of the substrate 16 to the side opposite to the design layer 14 side, and bends perpendicularly to the lower end direction of the substrate 16 in the middle. The groove portion 30 is formed by 16. Two back side protruding portions 22 are provided in the vicinity of the center of the back surface of the substrate 16 along the horizontal direction (long side direction).

As shown in FIGS. 6 and 7, the upper edge portion 26 of the upper projecting portion 18 is provided with a plurality of attachment holes 26 a for attaching the siding material 10 to an attachment surface such as an outer wall of a building. The siding material 10 can be fixed to the mounting surface by bringing the back surface of the upper edge 26 into contact with the mounting surface and screwing, nailing or the like using the mounting hole 26a.
Further, when the plurality of siding materials 10 are continuously attached to the attachment surface in the vertical direction, the groove portion 30 of the siding material 10 and the ridge 28 of the other siding material 10 attached to the lower side thereof are engaged, The upper and lower siding materials 10 are not easily separated.
Further, when the siding material 10 is attached to the attachment surface, not only the back surface of the upper edge portion 26 of the upper protrusion portion 18 but also the tip surface of the rear protrusion portion 22 contacts the attachment surface, and the substrate 16 is stably supported. It has come to be.

The synthetic resin constituting the resin molded body 12 is preferably a thermoplastic resin from the viewpoint of moldability and the like. Examples of the thermoplastic resin include polyolefin resins such as vinyl chloride resin, polycarbonate resin, polyethylene, and polypropylene. Of these, vinyl chloride resin is preferred in that it has moisture permeability and hardly undergoes freezing destruction and has high resistance to salt damage, acid and alkali.
The synthetic resin may be blended with additives such as fillers, reinforcing materials, pigments, processing aids, heat stabilizers, and ultraviolet absorbers as necessary.

The design layer 14 is a layer that is formed on the surface side of the substrate 16 and imparts excellent design properties. For example, a primer layer and a resin that is formed on the primer layer and in which inorganic particles are dispersed in a synthetic resin. A laminate having a three-layer structure comprising an intermediate coating layer formed of the composition and a topcoat layer formed on the intermediate coating layer is exemplified. A design (grained pattern or the like) is imparted to the design layer 14 depending on the type, size, dispersion state, and the like of the inorganic particles contained in the intermediate coating layer.
Examples of the synthetic resin used for the intermediate coating layer include acrylic resin, silicone resin, urethane resin, and fluorine resin.
Examples of the inorganic particles include natural crushed stones, pebbles, mica, silica sand, glass, colored aggregates, ceramic chips (chromium oxide, titanium oxide, zirconium oxide, aluminum oxide, tungsten carbide, chromium carbide, etc.). Can be mentioned.

<Mold>
Hereinafter, as an example of the mold of the present invention, a mold 100 used for manufacturing the siding material 10 will be described with reference to FIGS.
The mold 100 is a part made of synthetic resin in the siding material 10, and the resin molded body 12 in which the substrate 16, the upper projecting portion 18, the lower projecting portion 20, and the rear projecting portion 22 are integrated is extruded. It is a mold to do.
As shown in FIGS. 1 and 2, the mold 100 includes six blocks of a first block 102, a second block 104, a third block 106, a fourth block 108, a fifth block 110, and a sixth block 112 in order. It is connected.

As shown in FIG. 2, a resin flow path 114 through which the molten resin flows is formed in the mold 100 from the first block 102 to the sixth block 112.
The resin flow path 114 has an introduction part 116 formed in the first block 102 into which the molten resin is introduced; and the expansion formed in the second block 104 where the flow path gradually increases from the introduction part 116 side. Part 118; and a reduction part 120 formed from the third block 106 to the sixth block 112 and having a flow path that gradually decreases from the enlargement part 118 side.
In the mold 100, a molten resin in which the synthetic resin forming the resin molding 12 is melted is supplied from the supply port 102 a formed in the first block 102 to the resin flow path 114, and is circulated through the resin flow path 114. After being formed, the liquid is discharged from the discharge port 112a formed in the sixth block 112.

  The cross-sectional shape of the introduction portion 116 (the shape of the cross section of the flow path cut along a plane perpendicular to the flow direction (MD direction) of the molten resin. The same applies to the cross-sectional shapes of other flow paths). Instead, a circular shape, a rectangular shape, etc. are mentioned.

The enlarged portion 118 has a cross-sectional shape when the cross-sectional shape of the flow path is cut by a plane perpendicular to the MD direction in the formed resin molded body 12 (hereinafter simply referred to as “the cross-sectional shape of the resin molded body 12”). The flow path gradually increases from the introduction part 116 side so as to be larger than
The enlarged portion 118 is a portion that shapes the shape of the supplied molten resin into a shape corresponding to the shape of the resin molded body 12 to some extent in the resin flow path 114. Since the cross-sectional shape of the molten resin in the mold 100 is shaped to be equal to the cross-sectional shape of the resin molded body 12 at the reduced portion 120, the enlarged portion 118 has the upper protruding portion 18, the lower protruding portion 20, and the back side. It is not necessary to shape precisely according to the shape of the projecting portion 22 or the like, and the shape may not be completely similar to the resin molded body 12.

It is important that the enlarged portion 118 has a sufficient distribution of the molten resin throughout the flow path in the reduced portion 120 on the downstream side.
In the present invention, as in the enlarged portion 118 of this example, each of the flow paths as a whole is within a range in which the cross-sectional shape gradually increases so as to be larger than the cross-sectional shape of the resin molded body 12 as shown below. It is preferable that the flow path shape of the part has changed. Specifically, at both end portions 118b and 118b in the TD direction of the enlarged portion 118, the height of the flow path gradually increases from the introduction portion 116 side to the reduction portion 120 side, as shown in FIG. In the central portion 118a of the portion 118 in the TD direction, as shown in FIG. 3, the flow passage cross section is such that the height of the flow passage gradually increases from the introduction portion 116 side and then decreases in the vicinity of the reduction portion 120. Preferably it has changed.
In other words, the reduction section 120 side of the enlarged portion 118, TD opposite end portions 118b, at 118b, the distance _{d 2} between the upper wall surface 118c and a lower wall surface 118d corresponding to the front and back surfaces of the substrate 16, the distance in the central portion 118a d _The both end portions 118b and 118b are wider than the central portion 118a in the TD direction and have a wider channel shape. Therefore, as shown in FIG. 2, the molten resin supplied from the introduction part 116 to the center part 118 a in the TD direction in the enlarged part 118 is being spread toward the both end parts 118 b and 118 b in the TD direction in the enlarged part 118. Then, it is distributed to the reduction unit 120 side. As a result, the molten resin is sufficiently distributed to both end portions 118b and 118b in the TD direction of the enlarged portion 118, and as a result, the molten resin is sufficiently distributed to both end portions 120b and 120b in the TD direction of the reduced portion 120 on the downstream side. Therefore, in the molded resin body 12 to be molded, problems such as chipping occur at both ends of the substrate 16 in the TD direction, and at the upper protruding portion 18 and the lower protruding portion 20 provided at both ends of the substrate 16. Is suppressed.

As an aspect in which the enlarged portion 118 has such a shape, for example, on the reduced portion 120 side of the enlarged portion 118, either one or both of the upper wall surface 118c and the lower wall surface 118d corresponding to the front and back surfaces of the substrate 16 are arranged in the center. The aspect which curves so that those wall surfaces may protrude in the part 118a is mentioned.
The cross-sectional area of the flow path cross section at the end of the enlargement part 118 on the reduction part 120 side is preferably 2 to 10 times the cross-sectional area when the resin molded body 12 is cut by a plane perpendicular to the MD direction. 3 to 6 times is more preferable.

The reduced portion 120 is a portion that shapes the cross-sectional shape of the molten resin into a shape equivalent to the cross-sectional shape of the target resin molded body 12.
As shown in FIGS. 2 to 4, the cross-sectional shape of the reduced portion 120 gradually decreases from the enlarged portion 118 side so that the cross-sectional shape is the same as the cross-sectional shape of the formed resin molded body 12. . Thereby, in the enlarged portion 118, the cross-sectional shape of the molten resin shaped into a shape larger than that of the target resin molded body 12 is gradually narrowed down to become a shape equivalent to the cross-sectional shape of the resin molded body 12. Is done.
Specifically, in the reduced portion 120 of this example, both end portions 120b and 120b in the TD direction in the flow channel are larger than the central portion 120a on the enlarged portion 118 side, and the flow channel becomes gradually smaller. Finally, the cross-sectional shape of the flow path at the discharge port 112 a is the same shape as the cross-sectional shape of the resin molded body 12.

  Since the molten resin pushed away from the upstream side of the flow path is more likely to flow in the MD direction than in the TD direction, when the molten resin flows through the gradually increasing flow path, both ends of the flow path in the TD direction are provided. Tends to be difficult to supply molten resin. On the other hand, when the molten resin flows through the gradually decreasing flow path, since the molten resin flows densely, the possibility that a portion where the molten resin is not sufficiently supplied is newly generated in the flow path is small. . In the mold 100, since the molten resin is sufficiently spread to both end portions 118b and 118b having a wider flow path in the enlarged portion 118 as compared to the central portion 118a in the TD direction, the central portion 120a is also in the reduced portion 120. In addition, the state where the molten resin is sufficiently spread over the entire flow path of both ends 120b and 120b is maintained. Thereby, since it is suppressed that the part lacking in the molten resin discharged from the discharge port 112a arises, the high quality resin molding 12 can be shape | molded.

  Further, the flow path of the portion that forms the protrusion 28, the upper edge portion 26, the lower end portion of the substrate 16, the lower protruding portion 20, and the back protruding portion 22 in the reduced portion 120 is the flow path of the reduced portion 120. In the middle, it is preferable that the front end side of those portions becomes wide. Accordingly, it is possible to ensure that the molten resin is sufficiently filled on the front end side in each of the flow path portions, so that the substrate 16, the upper edge portion 26, the ridge 28, the lower protruding portion 20 and the rear protruding portion are provided. It can suppress more stably that a tip part of part 22 arises.

In a conventional mold such as the above-described mold 200, the molten resin may not be sufficiently distributed to both end portions in the TD direction in the enlarged portion 214 of the resin flow path 210. It is considered that a defect such as chipping may occur at the end of the plate.
On the other hand, in the mold 100, the flow path shape of the enlarged portion 118 is a flow path shape whose both end portions 118b and 118b are wider than the central portion 118a in the TD direction. Therefore, when the molten resin supplied to the resin flow path 114 is shaped in the enlarged portion 118, the molten resin is sufficiently distributed to both end portions 118b and 118b in the TD direction of the enlarged portion 118. In addition, the molten resin shaped into a cross-sectional shape larger than the cross-sectional shape of the resin molded body 12 in the enlarged portion 118 is shaped into the shape of the resin molded body 12 so as to be gradually reduced in the reduced portion 120. Therefore, even in the reduced portion 120, the molten resin is sufficiently filled over the entire flow path. Therefore, a high-quality resin molded body 12 is obtained that is free from defects such as chipping at both ends of the substrate 16, the upper edge portion 26, the protrusion 28, the lower projecting portion 20, and the rear projecting portion 22. It is done.

In addition, the metal mold | die of this invention is not limited to the metal mold | die 100 which shape | molds the resin molding 12 in the siding material 10. FIG. For example, the central portion in the TD direction of the flow path in the enlarged portion may not be reduced in the vicinity of the reduced portion, and may gradually increase from the introduction portion side to the reduced portion side. Further, in this manner, in the case where the central portion in the TD direction of the enlarged portion gradually increases from the introduction portion side to the reduction portion side, the proportion of the flow passages at both ends is increased compared to the central portion. Thus, on the reduced portion side of the enlarged portion, the flow path may be wider at both end portions than at the central portion in the TD direction.
Moreover, although the metal mold | die 100 was what the some block from the 1st block 102 to the 6th block 112 was connected, the metal mold | die which combines an upper mold | type and a lower mold | type may be sufficient.
Moreover, the metal mold | die which shape | molds the resin molding from which the shape and position of a protrusion part differ may be sufficient. Moreover, the metal mold | die which shape | molds the resin molding of uses other than siding materials, such as a deck material and an interior material, may be sufficient.

<Production Method of Resin Molded Body and Siding Material>
Hereinafter, the manufacturing method of the siding material 10 is demonstrated as an example of the manufacturing method of the siding material of this invention. As a manufacturing method of the siding material 10, the method which has the following formation process and a decoration process is mentioned, for example.
Molding step: a step of molding the resin molded body 12 by extrusion molding using the mold 100.
Decoration process: The process of forming the design layer 14 on the surface of the substrate 16 in the resin molded body 12.

(Molding process)
The molten resin is extruded so that the cross-sectional shape of the molten resin becomes the cross-sectional shape of the resin molded body 12, and the resin molded body 12 is molded by cooling while maintaining the shape.
At the time of molding, a synthetic resin may be foamed to form a foam. Thereby, the resin molding 12 can be reduced in weight. As a method of foaming the synthetic resin, for example, an inorganic foaming agent (carbonate or the like) or an organic foaming agent (thermal decomposition type or reaction type) is added and heated to the decomposition temperature to generate gas. Is mentioned.
As a method for cooling the molten resin extruded from the mold 100, any method can be used as long as it can form the resin molded body 12 by cooling while maintaining the shape. For example, a known cooling facility such as a sizer is used. Can do.

(Decoration process)
The method for forming the design layer 14 on the surface side of the substrate 16 in the resin molded body 12 may be selected as appropriate depending on the type of the design layer 14 to be formed, and is not particularly limited.
For example, in the case where a primer layer, an intermediate coating layer formed of a resin composition in which inorganic particles are dispersed in a synthetic resin, and a design layer having a three-layer structure including a topcoat layer are formed on the surface of the substrate 16, the following A method is mentioned.
First, a primer agent is applied to the surface of the substrate 16 and dried to form a primer layer. Thereafter, a mixture of the synthetic resin emulsion and the inorganic particles forming the intermediate coating layer is applied on the primer layer and dried to form the intermediate coating layer. Further, a coating material in which a transparent resin (acrylic-silicon resin, fluorine resin, etc.) for forming the topcoat layer is dissolved or dispersed in a solvent is applied and dried to form the topcoat layer.

The method for applying the primer and the coating used for forming the topcoat layer is not particularly limited, and coating by roll coater, knife coater, or reciprocating spraying is preferable.
Moreover, the coating method of the mixture of the synthetic resin emulsion and the inorganic particles is not particularly limited, and coating by roll coater, knife coater, or gun spraying is preferable.
The drying method of each layer is not specifically limited, For example, drying with a drying furnace etc. are mentioned.

  In addition, in the formation of the intermediate coating layer, if necessary, after applying the mixture, and before drying the formed coating layer, the surface of the coating layer is subjected to trowel finish, roller finish, etc. (Straight, irregular shape, etc.) may be formed.

According to the method for manufacturing the siding material 10 described above, both ends of the substrate 16, the upper edge portion 26 and the protruding line 28 in the upper protruding portion 18, the lower protruding portion 20, and the tip of the back protruding portion 22. It is possible to suppress the occurrence of defects such as chipping in the part and the like, and the high quality siding material 10 can be obtained.
Note that the method for manufacturing the siding material of the present invention is not limited to the method for manufacturing the siding material 10 described above. For example, the method which does not have a decoration process may be sufficient.

  Moreover, the manufacturing method of the resin molding of this invention should just be a method which has a shaping | molding process using the metal mold | die of this invention like the above-mentioned shaping | molding process, and is not limited to the manufacturing method of a siding material. For example, the manufacturing method of the resin molding for uses, such as a deck material and an interior material, may be sufficient.

  DESCRIPTION OF SYMBOLS 10 ... Siding material, 12 ... Resin molding, 14 ... Design layer, 16 ... Board | substrate, 18 ... Upper protrusion part, 20 ... Lower protrusion part, 22 ...・ Back side protruding portion, 24... Upper end surface portion, 26... Upper edge portion, 28... Ridge, 30 .. groove portion, 100. ... introduction part, 118 ... enlargement part, 118a ... central part, 118b, 118b ... both ends, 120 ... reduction part.

Claims (3)

A mold for extruding a resin molded body having a substrate and a projecting portion projecting from the substrate,
Having a resin flow path through which the molten resin flows,
The resin flow path, the introduction part into which the molten resin is introduced;
An enlarged portion in which the flow passage gradually increases in the TD direction from the introduction portion side so that the cross-sectional shape of the flow passage is larger than the cross-sectional shape of the resin molded body;
A reduced portion in which the flow path is gradually reduced from the enlarged portion side so that the cross-sectional shape of the flow path is equivalent to the cross-sectional shape of the resin molded body,
In the reduced portion side within the enlarged portion, the height of the flow path of both ends of the TD direction is higher than the height of the flow path of the central portion, the flow path towards the opposite end portions than the center portion becomes wider A mold characterized by A method for producing a resin molded body having a substrate and a projecting portion projecting from the substrate,
The manufacturing method of the resin molding which has a shaping | molding process of shape | molding the said resin molding by the extrusion molding by the metal mold | die of Claim 1. A method of manufacturing a siding material having a substrate and a resin molded body having a protruding portion protruding from the substrate,
The manufacturing method of the siding material which has a shaping | molding process which shape | molds the said resin molding by the extrusion molding by the metal mold | die of Claim 1.

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