JP6947586B2 - Manufacturing method of plate-shaped resin molded product and plate-shaped resin molded product - Google Patents

Description

The present invention relates to a method for producing a plate-shaped resin molded body having a continuous pattern and a plate-shaped resin molded body, which is applied to top plates, side plates, shelf plates, etc. of kitchens and furniture.

Conventionally, a plate-shaped resin molded body commonly called artificial marble has been used as a top plate for kitchens and furniture. In such a plate-shaped resin molded body, generally, a liquid acrylic resin containing an inorganic filler such as aluminum hydroxide, a polyester resin, an epoxy resin, or the like is injected into a mold and heat-cured by pressing. It is manufactured by letting it.

As a technique for patterning such a plate-shaped resin molded body, in Patent Document 1 filed by the applicant of the present application, a plurality of insert bodies 11 are arranged on the upper surface of the lower mold body and a pressing member is placed on the insert body 11. 14 is arranged, and the upper mold 12 facing the lower mold 32 is brought close to each other to press the insert body 11 via the pressing member 14, while the base material 12 made of the thermosetting resin is placed on the lower mold and the upper mold. A method for producing a resin molded product, which is injected into a gap between molds and then pressed by a lower mold and / or an upper mold until the pressing member 14 is elastically deformed, is disclosed (claims of Patent Document 1). 1. See paragraphs [0038] to [0050] of the specification, FIG. 5 of the drawing, etc.).

Further, in Patent Document 2, an insert body 11 for expressing a plurality of pattern bodies 92 forming a partial pattern is placed on the lower mold body 52, and the insert body 11 moves on the lower mold body 52. The pressing member 14 which is prevented and has a gap leading to the inside is brought into contact with the insert body 11, and the pressing members 14 which are brought into contact with the insert body 11 are pressed by bringing the molds 51 and 52 close to each other. Disclosed is a method for producing a resin molded body in which a resin is infiltrated into the inside through a gap of a pressed pressing member 14 and then the resin is cured (claim 1, in the specification of Patent Document 1). Paragraphs [0047] to [0061], FIG. 5 of the drawing, etc.).

However, the manufacturing method of the resin molded product described in Patent Document 1 and Patent Document 2 is a manufacturing method for giving an independent partial pattern to the resin molded product, and a pattern in which similar patterns are repeated in close proximity or in the lateral direction. In the case of expressing a wide range of continuous patterns that cannot be expressed by only one pattern piece such as a long continuous pattern on a resin molded body, there are the following problems. That is, in the case of an independent partial pattern, it is not noticeable even if there is some rotation or movement when injecting the base resin into the plate-shaped resin molded body, but in the case of a continuous pattern, the patterns to be compared are close to each other. However, since it is continuous, there is a problem that even a slight deviation or rotation in millimeters is noticeable.

As a method for solving such a problem, if the injection pressure of the substrate resin is lowered and the injection filling is carried out slowly over a long period of time, it is possible to suppress the displacement and rotation of the pattern pieces. However, by doing so, there is a problem that the manufacturing time of the resin molded product is increased, which in turn increases the manufacturing cost of the resin molded product.

As shown in FIGS. 12 and 13, another solution to the above-mentioned problem will be described by exemplifying a continuous pattern 1 of hemp leaves as a continuous pattern. For example, as a method for producing a plate-shaped resin molded body having a continuous pattern, diamond-shaped (parallelogram) -shaped pattern pieces 10 and 10'forming the continuous pattern 1 of hemp leaves are used as a resin for the plate-shaped resin molded body. It is conceivable that they are arranged side by side in the mold and then pressed by a pressing member to form a continuous pattern.

However, if the sides where the diamond-shaped (parallelogram) patterned pieces 10, 10'are in contact with each other are straight, even if the base resin of the resin molded body is injected, even if it is pressed by the pressing member, it is in millimeters. It is not possible to prevent misalignment and rotation by several degrees, and when a continuous pattern is displayed on the resin molded body, there is a problem that the yield is worse than when an independent partial pattern is displayed. rice field.

Further, when the diamond-shaped pattern piece 10 is used, the width becomes long (see also FIG. 3: width W3 of the pattern piece 10> width W1 of the general piece 2), which causes a problem that the storage space becomes large. was there. Further, since the diamond-shaped pattern pieces 10 and 10'have sharp and elongated portions, there is a high possibility that the pattern pieces 10 and 10'will be damaged by being broken or chipped when being transported. was there.

Japanese Unexamined Patent Publication No. 2010-184441 Japanese Unexamined Patent Publication No. 2011-73347

Therefore, the present invention has been devised in view of the above-mentioned problems, and an object of the present invention is that even if the pattern displayed on the plate-shaped resin molded body is a continuous pattern, the pattern does not shift. At the same time, it is an object of the present invention to provide a method for manufacturing a plate-shaped resin molded body and a plate-shaped resin molded body, which are easy to store the pattern piece and are less likely to be damaged during transportation.

The method for producing a plate-shaped resin molded product according to claim 1 is a method for producing a plate-shaped resin molded product in which a base resin is injected into a pair of upper and lower molds and cured to produce a plate-shaped resin molded product. Prior to injecting the base resin, a pattern body installation step of installing a plurality of rectangular pattern body pieces forming a continuous pattern to be expressed on the surface of the plate-shaped resin molded body in the mold, and the upper and lower parts thereof. It has a substrate resin filling step of filling a pair of molds with the substrate resin, and restrains at least one of the four sides of the rectangular pattern piece so that the adjacent pattern pieces do not shift from each other. In addition to the engaging sides having irregularities, the pattern installation step is characterized in that these engaging sides are installed side by side in a state of being engaged with each other.

The method for manufacturing a plate-shaped resin molded product according to claim 2 is the method for manufacturing a plate-shaped resin molded product according to claim 1, wherein the unevenness of the engaging side is a zigzag straight line intersecting at an blunt angle in a plan view. It is characterized by having a shape-like unevenness or a curved shape-like unevenness.

The method for producing a plate-shaped resin molded product according to claim 3 is the method for producing a plate-shaped resin molded product according to claim 1 or 2, wherein in the pattern installation step, a resin spring which is a spring material made of a resin material. The substrate resin injection step is characterized in that the substrate resin is injected while pressing the pattern piece against any of the pair of molds by the repulsive force of the resin spring.

The plate-shaped resin molded body according to claim 4 is a plate-shaped plate-shaped resin molded body using a base resin as a base, and has a plurality of rectangular shapes forming a pattern to be exposed on the surface of the plate-shaped resin molded body. The pattern piece is embedded in the base resin, and at least one of the four sides of the rectangular pattern piece has an unevenness that restrains the adjacent pattern pieces from shifting from each other. It is characterized by being on the edge.

According to the method for manufacturing a plate-shaped resin molded body according to any one of claims 1 to 3, a state in which engaging sides having irregularities that restrain adjacent pattern pieces so as not to shift from each other are engaged with each other. Since a plurality of pattern pieces are installed side by side in the above, even if the pattern displayed on the plate-shaped resin molded body is a continuous pattern, the pattern does not shift. In addition, since the pattern does not shift even if the injection speed of the substrate resin is increased, the plate-shaped resin molded product can be manufactured in a short time, and the manufacturing cost can be reduced. Moreover, since the pattern piece has a rectangular shape, the pattern piece can be easily stored and the risk of damage during transportation is reduced.

In particular, according to the method for manufacturing a plate-shaped resin molded body according to claim 2, the unevenness of the engaging side is a zigzag linear unevenness or a curved unevenness that intersects at an obtuse angle in a plan view. There is less risk of damage to the uneven portion of the engaging side when transporting the body piece.

In particular, according to the method for manufacturing a plate-shaped resin molded product according to claim 3, the substrate resin is injected while pressing the pattern piece into one of the pair of molds by the repulsive force of the resin spring. When injecting, there is less possibility that the continuous pattern will be misaligned. Therefore, the injection speed of the substrate resin can be further increased, the plate-shaped resin molded product can be manufactured in a short time, and the manufacturing cost can be reduced.

According to the plate-shaped resin molded body according to claim 4, at least one of the four sides of the rectangular pattern piece is an engaging side having unevenness that restrains adjacent pattern pieces from shifting from each other. Therefore, even if the displayed pattern is a continuous pattern, the pattern does not shift. Further, since the pattern does not shift even if the injection speed of the substrate resin is increased, the plate-shaped resin molded product can be manufactured in a short time, and the manufacturing cost can be reduced. Moreover, since the pattern piece has a rectangular shape, it is easy to store the pattern piece, and there is little risk of damage when the pattern piece is transported.

It is a top view which shows the plate-shaped resin molded article which concerns on 1st Embodiment of this invention. It is a partial enlarged view which shows the continuous pattern part of the plate-shaped resin molded article of the same above. It is the figure which compared the shape of the pattern body piece of the plate-shaped resin molded body of the same above, (a) is a diamond-shaped pattern body piece, (b) is the pattern body piece which concerns on embodiment of this invention. It is an enlarged plan view which shows the general piece of the pattern piece which concerns on embodiment of this invention. It is an enlarged plan view which shows the end piece of the pattern piece which concerns on embodiment of this invention. It is a partially enlarged sectional view which shows the pattern piece part of the plate-shaped resin molded body which concerns on 1st Embodiment. It is a figure which shows the resin spring which presses the pattern body piece which concerns on embodiment of this invention, (a) is a plan view, (b) is a side view. It is a top view which shows the installation place of the holding member which concerns on embodiment of this invention. It is a process explanatory drawing explaining each process of the manufacturing method of the plate-shaped resin molded article which concerns on embodiment of this invention. It is a top view which shows the plate-shaped resin molded article which concerns on 2nd Embodiment of this invention. It is an enlarged plan view which shows the end piece of the pattern body piece used for the plate-shaped resin molded body of the same above. It is a partial enlarged view which shows the arrangement state of the pattern body piece when the continuous pattern part of the plate-shaped resin molded body shown in FIG. 2 is expressed by the diamond-shaped pattern body piece. It is a partially enlarged view which shows the diamond-shaped pattern piece of FIG. 12 in an enlarged manner.

Hereinafter, a method for producing a plate-shaped resin molded product to which the present invention is applied and a mode for carrying out the plate-shaped resin molded product will be described in detail with reference to the drawings.

[First Embodiment]
First, the plate-shaped resin molded product according to the first embodiment of the present invention will be described with reference to FIGS. 1 to 8. A worktop WT of an I-type kitchen will be illustrated as a plate-shaped resin molded body according to the first embodiment, and a case where a continuous pattern 1 of hemp leaves is displayed on the surface of the worktop WT as a continuous pattern will be illustrated and described.

FIG. 1 is a plan view showing a worktop WT of a kitchen which is a plate-shaped resin molded product according to a first embodiment of the present invention, and FIG. 2 is a partially enlarged view showing a continuous pattern 1 of the worktop WT. be. As shown in FIG. 1, the kitchen worktop WT is a resin work plate generally called artificial marble that constitutes the top plate of the kitchen, and is used by being placed and fixed in the kitchen cabinet.

This worktop WT is a rectangular plate-like body having a width of about 2650 mm and a depth of about 980 mm, and as shown in FIG. 1, for installing a sink S and a gas stove C in order to function as a kitchen worktop. Two openings are formed. Of course, the dimensions and the like of the worktop WT are appropriately set according to the size of the kitchen, and in particular, the width and the like are different for each product.

Then, as shown in FIG. 1, the worktop WT is formed with a continuous pattern 1 of hemp leaves as a decoration of the surface portion to be the top surface. As will be described in detail later, this continuous pattern 1 will be described in detail later, but as shown in FIG. 2, a plurality of patterns made of resin preformed separately from the base resin FP (base resin: also see FIG. 6) of the worktop WT. The pieces (general piece 2, end piece 2') are arranged side by side in a pair of upper and lower molds (pressing device 50), and the base resin is poured into the pieces (general piece 2, end piece 2') to be solidified and integrally formed.

As the worktop WT according to the present embodiment, a base resin FP (base resin) in which an inorganic filler such as aluminum hydroxide or silicon dioxide is mixed with an acrylic resin is adopted. Of course, the substrate resin according to the present invention is not limited to the acrylic resin, and may be another resin such as a polyester resin or an epoxy resin, and may not contain an inorganic filler, or may contain other fillers or reinforcing fibers. Needless to say, it may be blended. In short, the substrate resin according to the present invention can be cured later to integrate the pattern piece (general piece 2, end piece 2') in a fluidized state at the time of filling, and can be used as a worktop after curing. It may be a thermosetting resin or a thermoplastic resin having a certain surface hardness for functioning.

The continuous pattern 1 is a geometric continuous pattern in which a pattern of the same shape with a 6-leaf hemp leaf motif appears repeatedly and continuously (see also FIG. 4), and as shown in FIG. 2, a plurality of pattern pieces. It is composed of (general piece 2, end piece 2'). Although there are independent partial patterns as described in the background technology, the decorative pattern of the conventional resin worktop is a single color such as beige, white, black, pink, or a marble-like flow pattern or sand pattern in a single color. Is the majority, and such continuous pattern decoration is difficult and has not been realized. It is an object of the present invention to display such a continuous pattern neatly on a plate-shaped resin molded product without shifting.

As shown in FIG. 2, among the pattern pieces constituting the continuous pattern 1, the pattern piece in which other pattern pieces are arranged on both sides is the general piece 2, and the pattern at the end located at the right end is the general piece 2. The body piece is the end piece 2'. The gradation portion at the left end of the continuous pattern 1 is composed of an independent pattern piece that is not adjacent to other pattern pieces or an amorphous pattern piece.

3A and 3B are views comparing the shapes of the patterned pieces, in which FIG. 3A shows a diamond-shaped patterned piece 10 and FIG. 3B shows a general piece 2 of the patterned piece according to the embodiment of the present invention. ing. As described in the background technique, it is also conceivable that the pattern piece that constitutes the continuous pattern 1 is the rhombus (parallelogram) -shaped pattern piece 10 shown in FIG. 3 (a).

However, as shown in FIG. 3A, when the sides where the diamond-shaped (parallelogram) -shaped patterned pieces 10 are in contact with each other are straight (see also FIGS. 9 and 10), when the substrate resin is injected. In addition, there is a problem that even if the pressing member (resin spring 3) described later is pressed, it is not possible to prevent the deviation in millimeters and the rotation in several degrees. Therefore, when the continuous pattern 1 is displayed on the worktop WT which is a resin molded body, there is a problem that the yield is deteriorated as compared with the case where the independent partial pattern is displayed.

Therefore, in the worktop WT according to the present embodiment, as shown in FIG. 3B, the schematic shape of the pattern piece that constitutes the continuous pattern 1 is rectangular, and the left and right sides of the four sides are zigzag. The engaging side has linear unevenness.

FIG. 4 is an enlarged plan view of the above-mentioned general piece 2 enlarged so that the shapes of the hemp leaf and the engaging side can be seen. As shown in FIG. 4, as shown by a thick line, the general piece 2 is a patterned piece having an upper side 20, a lower side 21, a left side 22, and a right side 23 having a substantially rectangular shape. Of course, the rectangular shape means that, as shown by the thick line in FIG. 4, the rough shape of the pattern piece does not have an elongated protruding portion as compared with the diamond-shaped pattern piece shown in the figure. It does not only refer to rectangular pieces with right-angled corners.

As shown in FIG. 4, the upper side 20 and the lower side 21 are linear sides, and the left side 22 and the right side 23 are engaging sides having zigzag linear unevenness according to the contour shape of the hemp leaf. ing. By setting the left side 22 and the right side 23 as engaging sides having irregularities, the general pieces 2 (patterned pieces) adjacent to the left and right are restrained from being displaced from each other when the base resin is poured into the mold and cured. can do.

Further, the zigzag linear unevenness is all composed of obtuse angles, and there is less possibility that the uneven portion of the engaging side will be damaged when the pattern piece is transported. Of course, the unevenness of the engaging side may be gently curved according to the continuous pattern. By making the unevenness of a zigzag straight line or a gentle curved line having an obtuse angle, it is possible to eliminate the elongated protruding portion and reduce the possibility of breaking or chipping.

FIG. 5 is an enlarged plan view of the above-mentioned end piece 2'enlarged so that the shapes of the hemp leaf and the engaging side can be seen. As shown in FIG. 5, the end piece 2'is, as shown by a thick line, a patterned piece having an upper side 20', a lower side 21', a left side 22', and a right side 23', which are generally rectangular. The upper side 20', the lower side 21', and the right side 23'are linear sides, and the left side 22'has a zigzag linear unevenness that engages with the right side 23 of the adjacent general piece 2. It is a side of an equation.

Further, as shown in FIGS. 4 and 5, the general piece 2 and the end piece 2', which are these pattern pieces, are both machined from one resin plate to form the substrate portion P1 and the pattern portion P2. It is a formed resin piece, and a large number of through holes h1 for entering and integrating the base resin are bored.

The width W1 of the general piece 2 and the width W2 (width of the pattern piece) of the end piece 2'are preferably 300 mm to 330 mm or less in consideration of storage and transportation by one person with both hands. This is because if the width of the pattern piece is too large, it will be difficult for one person to carry it, and the risk of damage will increase.

(Pressing member)
Next, with reference to FIGS. 6 to 8, a pressing member for pressing and fixing these pattern pieces to prevent the pattern pieces from shifting in the mold and a method of using the pressing member will be described. FIG. 6 is a partially enlarged cross-sectional view showing a pattern piece portion of the worktop WT, and FIG. 7 is a view showing a pressing member for pressing the pattern piece of the worktop WT. FIG. ) Is a side view. Further, FIG. 8 is a plan view showing a location where the pressing member is installed.

As shown in FIG. 6, a pressing member for preventing the pattern piece from shifting when the base resin FP is injected and filled is embedded in the worktop WT. The pressing member according to the present embodiment is a resin spring 3 made of synthetic resin such as integrally molded polycarbonate. Of course, the pressing member according to the present invention is not limited to the one made of resin, but is made of an elastic material such as a general steel coil spring or leaf spring and is installed by being compressed. It goes without saying that any member that can press the piece can be applied regardless of the material.

The lower part of FIG. 6 is the surface (top surface) of the worktop WT, and the general piece 2 (pattern piece) is pressed by the resin spring 3 (pressing member) against the lower frame (not shown). , The continuous pattern 1 appears on the surface of the worktop WT.

As shown in FIG. 7 (a), the resin spring 3 has a spiral notch 30 penetrating the resin material, and as shown in FIG. 7 (b), the remaining portion has a bottom surface 31 as a plate. It is a spiral tapered spring with a taper that protrudes downward from the portion 32 and shrinks in diameter as it goes downward.

Further, as shown in FIG. 7A, a through hole 33 is formed in the center, and the base resin FP enters the through hole 33 and the notch 30, so that the worktop WT is integrated. Therefore, the plate portion 32 may be exposed as it is on the back surface of the worktop WT (see FIG. 6), and it is better to use a synthetic resin like the resin spring 3 which is the pressing member according to the present embodiment. It can be said that it is preferable from the viewpoint of rust and integration.

As shown in FIG. 8, it is preferable that the resin spring 3 is installed near the four corners of the back surface (internal side surface) of the general piece 2 (patterned body piece). Of course, the place where the resin spring 3 is installed is a place where the pattern piece can be pressed in a well-balanced manner, such as installing the resin spring 3 in a portion close to each other so as to straddle the general pieces 2 or installing only one large pressing member in the center. May be selected as appropriate.

<Method for manufacturing a plate-shaped resin molded product according to an embodiment of the present invention>
Next, a method for producing the plate-shaped resin molded product according to the embodiment of the present invention will be described with reference to FIG. The case where the continuous pattern 1 is displayed on the worktop WT described above will be described as an example. FIG. 9 is a process explanatory view showing each process of the worktop WT manufacturing method.

(1) Pattern Installation Step First, as shown in step S1 of FIG. 9, in the method for manufacturing a plate-shaped resin molded body according to the present embodiment, a pattern installation step of installing a plurality of pattern pieces in a mold is performed. conduct.

Specifically, in a state where the pair of upper and lower resin molds (lower frame 51, upper frame 52) of the press device 50 are opened, that is, in a state where the upper frame 52 is moved upward, the pattern piece is placed on the lower frame 51. The above-mentioned general piece 2 and end piece 2'are arranged side by side.

At this time, the pattern pieces are arranged side by side so that the unevenness of the engaging sides of the pattern pieces mesh with each other. Further, as described above, the resin spring 3 which is a pressing member is placed near the four corners of each piece such as the general piece 2 and the end piece 2'.

(2) Mold clamping step Next, as shown in step S2 of FIG. 9, in the method for manufacturing a plate-shaped resin molded body according to the present embodiment, the upper frame 52 of the press device 50 is lowered to form a pair of upper and lower resin molds. Perform a mold clamping process to close the mold. The upper frame 52 is lowered until the distance between the lower frame 51 and the upper frame 52 becomes about the thickness of the worktop WT. Of course, the lower frame 51 may be raised, the upper frame 52 may be lowered, and the lower frame 51 may be raised. In short, it suffices if the press device 50 can be closed.

By this step, the resin spring 3 placed on the pattern piece in the previous step is compressed, and each piece such as the general piece 2 and the end piece 2'is pressed against the lower frame 51 by the repulsive force. Become. Therefore, when the substrate resin FP is injected and filled in the subsequent process, the possibility that the pattern pieces are displaced or rotated is reduced.

(3) Substrate Resin Filling Step Next, as shown in Tep S3 of FIG. 9, in the method for manufacturing a plate-shaped resin molded product according to the present embodiment, the lower frame 51 of the press device 50 that has been mold-clamped in the previous step. The substrate resin filling step of filling the space between the upper frame 52 and the substrate resin FP described above is performed.

Specifically, the fluidized substrate resin FP is poured into the space between the lower frame 51 and the upper frame 52 at a pressure of about 0.2 MPa through a tube or the like to be injected / filled. At this time, each pattern piece is pressed against the lower frame 51 by the resin spring 3, and the pattern pieces are engaged with each other by the unevenness of the engaging side. Even if the pattern pieces are hung, the pattern pieces do not shift or rotate with each other. Therefore, the above-mentioned continuous pattern 1 composed of the general piece 2 and the end piece 2'does not be displaced.

Further, by engaging the pattern pieces with each other at the engaging side, even if the injection pressure of the base resin FP injected at about 0.06 MPa is increased to about 0.2 MPa and injected, the pattern pieces will be injected with each other. It no longer shifts or rotates. Therefore, the injection time of the substrate resin FP can be significantly shortened, and the present process can be completed in a short time.

The lower frame 51 and the upper frame 52 are preferably sealed with a sealing material (not shown) such as a gasket so that the base resin FP does not leak out. Further, the method of filling the substrate resin FP is not limited to the case of injecting from a tube or the like, and a bulk or sheet-shaped resin may be charged, and the method of filling the resin is not limited.

Then, prior to or at the same time as filling the base resin FP, a preheating step of preheating with the heating wire HL wired to the lower frame 51 and the upper frame 52 is also performed. The heating temperature at this time is a temperature at which the substrate resin FP does not cool and solidify, and the temperature is maintained. This is to eliminate the temperature difference between the pattern piece or the resin spring 3 and the base resin FP, prevent the occurrence of gaps, and perform reliable molding. Of course, this preheating step may be omitted if necessary, and heating may be started from the pattern piece installation step. Further, the heating is not limited to the heating wire HL, and any heating means may be used for heating.

(4) Heating and Pressurizing Step Next, as shown in step S4 of FIG. 9, in the method for producing a plate-shaped resin molded product according to the present embodiment, the base resin FP is cured by heating with a heating wire HL, and the substrate resin FP is cured. A heating and pressurizing step of tightening and pressurizing the press device 50 is performed.

Specifically, the substrate resin FP, which is a thermosetting resin, is heated by the heating wire HL to a temperature suitable for curing, and the upper frame 52 of the press device 50 is lowered or the lower frame 51 is raised to raise the lower frame 51. Pressurize by reducing the distance between the upper frame 52 and the upper frame 52 by a small amount of about 1 mm from the previous step. By this step, the substrate resin FP can be integrated with the pattern piece and the resin spring 3.

(5) Cooling and Demolding Step Next, as shown in FIG. 9D, in the method for producing a plate-shaped resin molded product according to the present embodiment, as step S4, the substrate resin FP heated in the previous step is cooled. After that, the press device 50 is opened to perform a cooling demolding step of demolding the worktop WT.

Specifically, the heating of the lower frame 51 and the upper frame 52 by the heating wire HL is stopped, and the substrate resin FP and the worktop WT heated in the previous step by natural cooling are left to cool until they reach about room temperature. Then, after confirming that the temperature of the worktop WT has dropped to about room temperature, the upper frame 52 of the press device 50 is raised or the lower frame 51 is lowered to open the mold, and the substrate resin FP is cured and integrated. Demold the worktop WT.

With the completion of this step, the work of the method for manufacturing the worktop WT, which is a plate-shaped resin molded body, is completed, and the above-mentioned continuous pattern 1 appears on the surface of the worktop WT with a patterned piece such as the embedded general piece 2. Will be done.

According to the method for manufacturing the plate-shaped resin molded product according to the embodiment of the present invention and the plate-shaped resin molded product according to the embodiment of the present invention described above, adjacent patterned pieces (general piece 2 and end piece 2'). A plurality of patterned pieces are installed side by side in a state where the engaging sides (left side 22, right side 23, left side 22') having irregularities that restrain them from being displaced from each other are engaged with each other. Therefore, the continuous pattern 1 displayed on the worktop WT, which is a plate-shaped resin molded body, does not shift. In addition, since the pattern does not shift even if the injection speed of the substrate resin is increased, the worktop WT can be manufactured in a short time, and the manufacturing cost can be reduced.

In addition, since the pattern piece has a rectangular shape with a width of 330 mm or less that can be held by one person, the pattern piece can be easily stored and the risk of damage during transportation is reduced. Further, since the unevenness of the engaging side (left side 22, right side 23, left side 22') is formed at an obtuse angle, there is less possibility that the uneven portion of the engaging side will be damaged when the pattern piece is transported.

[Second Embodiment]
Next, the plate-shaped resin molded product according to the second embodiment of the present invention will be briefly described with reference to FIGS. 10 and 11. The difference between the worktop WT, which is the plate-shaped resin molded product according to the second embodiment, and the worktop WT, which is the plate-shaped resin molded product according to the first embodiment, is that the worktop of the type I kitchen The point is that it is a worktop of an L-shaped kitchen. In addition, the continuous pattern 1'appearing on the surface of the worktop WT'is a continuous pattern whose left and right sides are reversed from the above-mentioned continuous pattern 1. Therefore, only that point will be described, and other explanations will be omitted.

FIG. 10 is a plan view showing the worktop WT'. As shown in FIG. 10, among the pattern pieces constituting the continuous pattern 1', the pattern piece in which other pattern pieces are arranged on both sides is the above-mentioned general piece 2, and the end located at the left end. The pattern piece of the part is the end piece 2 ". The gradation part at the right end of the continuous pattern 1'is composed of an independent pattern piece in which no other pattern piece is adjacent or an irregular pattern piece. There is.

FIG. 11 is an enlarged plan view of the end piece 2 "enlarged so that the shape of the hemp leaf and the engaging side can be seen. As shown in FIG. 11, the end piece 2" has an upper side 20 ", a lower side 21", and a left side. It is a patterned piece composed of 22 "and 23" on the right side and having a rectangular shape. The upper side 20 ", the lower side 21", and the left side 22 "are linear sides, and the right side 23" has a zigzag linear unevenness that engages with the left side 22 of the adjacent general piece 2. It is a border.

As described above, the shape of the pattern piece that constitutes the continuous pattern can be appropriately changed according to the continuous pattern. However, the approximate shape of the pattern piece must be rectangular so that there is no elongated protruding part, and at least one of the four sides of the rectangular pattern piece is adjacent to each other. It is necessary to use an engaging side that restrains it so that it does not shift.

It should be noted that the rectangular pattern piece and the irregular pattern piece according to the present invention can be combined and engaged at the engaging side, or the independent partial pattern pattern pieces disclosed in Patent Documents 1 and 2. Of course, it is also possible to combine with.

The method for producing the plate-shaped resin molded product according to the embodiment of the present invention and the plate-shaped resin molded product according to the embodiment of the present invention have been described in detail above, but any of the above-mentioned or illustrated embodiments has been described in detail. It merely shows one embodiment embodied in carrying out the present invention. Therefore, the technical scope of the present invention should not be construed in a limited manner by these.

WT, WT': Worktop (plate-shaped resin molded body)
S: Sink C: Gas stove FP: Base resin 1, 1': Continuous pattern 2: General piece (pattern piece)
2', 2 ": End piece (patterned piece)
20, 20', 20 ": Upper side 21,21', 21": Lower side 22, 22': Left side (engagement side)
22 ": Left side 23, 23": Right side (engagement side)
23': Right side h1: Through hole 3: Resin spring (holding member)
30: Notch 31: Bottom part 32: Plate part 33: Through hole 50: Press device 51: Lower frame 52: Upper frame HL: Heating wire

Claims (4)

It is a method for manufacturing a plate-shaped resin molded product by injecting a base resin into a pair of upper and lower molds and curing the base resin to produce a plate-shaped resin molded product.
Before injecting the substrate resin, a pattern body installation step of installing a plurality of rectangular pattern body pieces forming a continuous pattern to be expressed on the surface of the plate-shaped resin molded body in the mold, and
It has a base resin filling step of filling the base resin in the pair of upper and lower molds.
At least one of the four sides of the rectangular pattern piece is an engaging side having unevenness that restrains the adjacent pattern pieces from shifting from each other.
In the pattern body installation step, a method for manufacturing a plate-shaped resin molded body, characterized in that these engaging sides are installed side by side in a state of being engaged with each other. The engagement unevenness of Gohen in plan view, a manufacturing method of the plate-like resin molded article according to claim 1, characterized in that the zigzag linear irregularities or curved irregularities that intersect at an obtuse angle. In the pattern installation step, a resin spring, which is a spring material made of a resin material, is installed, and in the base resin injection step, the pattern piece is pressed against one of the pair of molds by the repulsive force of the resin spring. The method for producing a plate-shaped resin molded product according to claim 1 or 2, wherein the base resin is injected while the base resin is injected. A plate-shaped plate-shaped resin molded product using a base resin as a substrate.
A plurality of rectangular pattern pieces forming a pattern to be exposed on the surface of the plate-shaped resin molded body are embedded in the base resin.
A plate-shaped resin molding characterized in that at least one of the four sides of the rectangular pattern piece is an engaging side having irregularities that restrain the adjacent pattern pieces from shifting from each other. body.

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