JP7646306B2 - Manufacturing method and molding material for marble-like molded products - Google Patents

Description

The present invention relates to a manufacturing method and molding material for marble-like molded products.

In recent years, there has been a study into adding marble-like patterns to resin molded products in order to improve their design.

For example, a method has been proposed for producing SMC molded products in which a thermosetting resin composition of a different color tone from the SMC is applied to the surfaces of multiple sheets of sheet molding compound (hereinafter referred to as SMC), and then the multiple SMCs are stacked and placed in a mold, followed by heating and pressurization (see, for example, Patent Document 1).

In such a manufacturing method for SMC molded products, when multiple stacked SMCs are heated and pressurized, the resin compound of the SMC flows and the thermosetting resin composition flows, forming a marble-like pattern on the SMC molded product.

JP 2015-229277 A

However, the manufacturing method for SMC molded products described in Patent Document 1 does not actually achieve a natural marble look that is close to that of natural marble.

The present invention provides a manufacturing method and molding material for marble-like molded products that can achieve a natural marble-like finish close to that of natural marble using a simple method.

The present invention [1] is a method for producing a marble-like molded product, comprising the steps of preparing a first resin material having a flake shape, mixing the first resin material with a powder pigment having a maximum dimension of 1000 μm or less to prepare a mixed material, and molding the mixed material.

The present invention [2] includes the method for producing the marble-like molded product described in [1] above, in which the powder pigment has a color and/or tone different from that of the first resin material.

The present invention [3] includes the method for producing a marble-like molded product described in [1] or [2] above, in which the step of preparing the first resin material includes a step of preparing a first resin molding compound made of the first resin material, and a step of cutting out the first resin material having a small piece shape from the first resin molding compound.

The present invention [4] includes the method for producing a marble-like molded product according to any one of the above [1] to [3], further comprising a step of preparing a second resin material that is different in color and/or tone from the first resin material and has a flake or liquid form, and in the step of preparing the mixed material, the first resin material, the powder pigment, and the second resin material are mixed.

The present invention [5] includes the method for producing the marble-like molded product described in [4] above, further comprising a step of preparing a third resin material that is different in color and/or tone from the first resin material and the second resin material and has a flake or liquid form, and in the step of preparing the mixed material, the first resin material, the powder pigment, the second resin material, and the third resin material are mixed.

The present invention [6] includes the method for producing the marble-like molded product described in [5] above, further including a step of preparing a fourth resin material that is different in color and/or tone from the first resin material, the second resin material, and the third resin material, and that is in a flake or liquid form, and in the step of preparing the mixed material, the first resin material, the powder pigment, the second resin material, the third resin material, and the fourth resin material are mixed.

The present invention [7] includes a molding material comprising a platelet-shaped first resin material and a powder pigment having a maximum dimension of 1000 μm or less.

In the method for manufacturing a marble-like molded product of the present invention, a first resin material having a small particle shape is mixed with a powder pigment having a maximum dimension of 1000 μm or less, and then the mixed material is molded.

Therefore, when the mixed material is molded, the first resin material, which has a small flake shape, and the powder pigment are mixed together to form a natural marbled look. As a result, a natural marbled look similar to that of natural marble can be achieved in the molded product, even with a simple method.

The molding material of the present invention comprises a platelet-shaped first resin material and a powder pigment having a maximum dimension of 1000 μm or less. Therefore, the molding material is suitable for use in the manufacturing method of the marble-like molded product described above, and can smoothly manufacture molded products having a natural marble-like texture close to that of natural marble.

FIG. 1 shows a photograph of the flat plate molded product of Example 1 in a plan view. FIG. 2 shows a photograph of the flat plate molded product of Example 2 in a plan view. FIG. 3 shows a photograph of the flat plate molded product of Example 3 in a plan view. FIG. 4 shows a photograph of the flat plate molded product of Example 4 in a plan view. FIG. 5 shows a photograph of the flat plate molded product of Example 5 in a plan view. FIG. 6 shows a photograph of the flat plate molded product of Example 6 in a plan view. FIG. 7 shows a photograph of the flat plate molded product of Example 7 in a plan view. FIG. 8 shows a photograph of the flat plate molded product of Example 8 in a plan view.

The method for producing a marble-like molded product of the present invention includes the steps of preparing a flake-shaped first resin material, mixing the first resin material with a powder pigment having a maximum dimension of 1000 μm or less to prepare a mixed material, and molding the mixed material.

First Embodiment
A first embodiment of the method for producing a marble-like molded product of the present invention will be described below.

1-1. Preparation of First Resin Material In the first embodiment, first, a first resin material having a flake shape is prepared (first preparation step). The first resin material is in a solid state that does not exhibit fluidity at room temperature (23° C.).

To prepare the first resin material having a small particle shape, for example, a first resin molding compound made of the first resin material is prepared, and then the first resin material having a small particle shape is cut out from the first resin molding compound. In other words, the process of preparing the first resin material includes a process of preparing a first resin molding compound made of the first resin material (molding compound preparation process) and a process of cutting out the first resin material having a small particle shape from the first resin molding compound (cutting process).

The first resin molding compound includes, for example, a first thermosetting resin composition and reinforcing fibers impregnated with the first thermosetting resin composition.

The first thermosetting resin composition includes, for example, a first thermosetting resin and a first colorant.

The first thermosetting resin includes a resin base and an ethylenically unsaturated monomer.

Specifically, the content of the ethylenically unsaturated monomer in the first thermosetting resin is, for example, 10% by mass or more, preferably 20% by mass or more, and, for example, 90% by mass or less, preferably 60% by mass or less.

Specific examples of the first thermosetting resin include a first unsaturated polyester resin, a first vinyl ester resin, and a first acrylic syrup. The first thermosetting resin can be used alone or in combination of two or more types.

In other words, the first thermosetting resin includes at least one selected from the group consisting of a first unsaturated polyester resin, a first vinyl ester resin, and a first acrylic syrup.

The first unsaturated polyester resin contains an unsaturated polyester as a resin base and an ethylenically unsaturated monomer.

Unsaturated polyester is a polymerization product (polymer) of polybasic acids and polyhydric alcohols.

The polybasic acid includes at least a polybasic acid having an ethylenically unsaturated double bond (hereinafter referred to as an ethylenically unsaturated bond-containing polybasic acid). The polybasic acid preferably further includes a polybasic acid not having an ethylenically unsaturated double bond (hereinafter referred to as an ethylenically unsaturated bond-free polybasic acid).

Examples of ethylenically unsaturated bond-containing polybasic acids include unsaturated alicyclic dibasic acids and acid anhydrides derived from unsaturated alicyclic dibasic acids.

Examples of unsaturated alicyclic dibasic acids include maleic acid, fumaric acid, and itaconic acid. Examples of acid anhydrides derived from unsaturated alicyclic dibasic acids include maleic anhydride.

The ethylenically unsaturated bond-containing polybasic acids can be used alone or in combination of two or more.

Among the ethylenically unsaturated bond-containing polybasic acids, preferred are acid anhydrides of unsaturated alicyclic dibasic acids, and more preferred are maleic anhydride.

Examples of polybasic acids that do not contain ethylenically unsaturated bonds include saturated aliphatic polybasic acids, saturated alicyclic polybasic acids, and aromatic polybasic acids.

Examples of saturated aliphatic polybasic acids include saturated aliphatic dibasic acids.

Examples of saturated aliphatic dibasic acids include oxalic acid, malonic acid, succinic acid, adipic acid, and sebacic acid.

Examples of saturated alicyclic polybasic acids include saturated alicyclic dibasic acids and acid anhydrides derived from saturated alicyclic dibasic acids.

Examples of saturated alicyclic dibasic acids include HET acid, 1,2-hexahydrophthalic acid, 1,1-cyclobutanedicarboxylic acid, 1,4-cyclohexanedicarboxylic acid (cis- or trans-1,4-cyclohexanedicarboxylic acid or a mixture thereof), and dimer acid.

An example of an acid anhydride derived from the above-mentioned saturated alicyclic dibasic acid is hexahydrophthalic anhydride.

Examples of aromatic polybasic acids include aromatic dibasic acids and acid anhydrides derived from aromatic dibasic acids.

Examples of aromatic dibasic acids include phthalic acid (orthophthalic acid, isophthalic acid, and terephthalic acid), trimellitic acid, and pyromellitic acid.

An example of an acid anhydride derived from the above aromatic dibasic acid is phthalic anhydride.

Among the polybasic acids not containing ethylenically unsaturated bonds, aromatic polybasic acids are preferred, aromatic dibasic acids are more preferred, phthalic acid is even more preferred, and isophthalic acid is particularly preferred.

The polybasic acids not containing ethylenically unsaturated bonds can be used alone or in combination of two or more types.

Examples of polyhydric alcohols include alkanediols, polyoxyalkylene glycols, alicyclic diols, and aromatic diols.

Examples of alkanediols include ethylene glycol, propylene glycol, butylene glycol, 1,5-pentanediol, 1,6-hexanediol, and neopentyl glycol.

Examples of polyoxyalkylene glycols include polyethylene glycol and polypropylene glycol. Examples of polyethylene glycols include diethylene glycol. Examples of polypropylene glycols include dipropylene glycol.

Examples of alicyclic diols include cyclohexanediol and hydrogenated bisphenol A.

An example of an aromatic diol is bisphenol. An example of a bisphenol is bisphenol A.

Polyhydric alcohols can be used alone or in combination of two or more types.

Among the polyhydric alcohols, alkanediols are preferred, propylene glycol and neopentyl glycol are preferred, and a combination of propylene glycol and neopentyl glycol is more preferred.

Such unsaturated polyesters are prepared by condensation polymerization of the above-mentioned polybasic acids and the above-mentioned polyhydric alcohols under known reaction conditions.

The unsaturated polyester preferably has an acid value.

Methods for preparing unsaturated polyesters with an acid value include, for example, a method of condensation polymerizing an excess of a polybasic acid relative to a polyhydric alcohol, and a method of terminating the condensation polymerization reaction between a polybasic acid and a polyhydric alcohol when the desired acid value is reached.

The acid value of the unsaturated polyester is, for example, 20 mgKOH/g or more, preferably 25 mgKOH/g or more, and, for example, less than 40 mgKOH/g, preferably 30 mgKOH/g or less. The acid value of the unsaturated polyester can be measured in accordance with JIS K6901 (2008).

The ethylenically unsaturated monomer is a polymerizable monomer (vinyl monomer) having an ethylenically unsaturated double bond. In the unsaturated polyester resin, the ethylenically unsaturated monomer is a reactive diluent that can dissolve the above-mentioned unsaturated polyester and can polymerize (crosslink) with the above-mentioned unsaturated polyester.

Examples of ethylenically unsaturated monomers include styrene-based monomers and (meth)acrylates. Note that (meth)acrylic is synonymous with methacrylic and/or acrylic (hereinafter the same). Ethylenically unsaturated monomers can be used alone or in combination of two or more kinds.

Among the ethylenically unsaturated monomers contained in the first unsaturated polyester resin, a styrene-based monomer is preferably used.

Examples of styrene-based monomers include styrene, α-methylstyrene, α-ethylstyrene, vinyltoluene, t-butylstyrene, and chlorostyrene.

The styrene monomers can be used alone or in combination of two or more types.

Among the styrene-based monomers, styrene is preferred.

The content of the ethylenically unsaturated monomer in the first unsaturated polyester resin is, for example, 10 parts by mass or more, preferably 30 parts by mass or more, and, for example, 90 parts by mass or less, preferably 60 parts by mass or less, per 100 parts by mass of the total of the unsaturated polyester and the ethylenically unsaturated monomer.

The first vinyl ester resin contains a vinyl ester as a resin base and the above-mentioned ethylenically unsaturated monomer.

Vinyl esters are the addition reaction products of epoxy resins and unsaturated monobasic acids.

Examples of epoxy resins include bisphenol-type epoxy resins, novolac-type epoxy resins, aliphatic-type epoxy resins, alicyclic epoxy resins, hydrogenated bisphenol-type epoxy resins, and amine-type epoxy resins.

Examples of bisphenol type epoxy resins include bisphenol A type epoxy resins, bisphenol F type epoxy resins, and brominated bisphenol A type epoxy resins.

Novolac type epoxy resins include, for example, phenol novolac type epoxy resins, cresol novolac type epoxy resins, and brominated novolac type epoxy resins.

Epoxy resins can be used alone or in combination of two or more types.

The unsaturated monobasic acid has an ethylenically unsaturated double bond. Examples of the unsaturated monobasic acid include unsaturated monofatty acids, aromatic unsaturated monocarboxylic acids, and ester bond-containing unsaturated monocarboxylic acids.

Examples of unsaturated mono-fatty acids include (meth)acrylic acid, crotonic acid, and sorbic acid.

An example of an aromatic unsaturated monocarboxylic acid is cinnamic acid.

Examples of unsaturated monocarboxylic acids containing ester bonds include reaction products of acid anhydrides and unsaturated alcohols.

Unsaturated monobasic acids can be used alone or in combination of two or more.

Such vinyl esters are prepared by a ring-opening addition reaction between the above-mentioned epoxy resin and the above-mentioned unsaturated monobasic acid under known reaction conditions.

Vinyl esters include unmodified vinyl esters (unmodified vinyl esters) as well as acid-modified vinyl esters derived from unmodified vinyl esters.

An acid-modified vinyl ester is a vinyl ester that has been acid-modified, and a carboxyl group has been introduced into the side chain of the vinyl ester. An acid-modified vinyl ester is, for example, a reaction product of the above-mentioned unmodified vinyl ester and an acid anhydride.

Examples of acid anhydrides include maleic anhydride, succinic anhydride, phthalic anhydride, tetrahydrophthalic anhydride, hexahydrophthalic anhydride, and trimellitic anhydride. The acid anhydrides can be used alone or in combination of two or more.

The acid-modified vinyl ester is prepared, for example, by reacting the hydroxyl group contained in the unmodified vinyl ester with the acid anhydride group of the acid anhydride under known reaction conditions. The reaction between the hydroxyl group and the acid anhydride group forms an ester bond and generates a carboxyl group.

In the first vinyl ester resin, the ethylenically unsaturated monomer is a reactive diluent that can dissolve the vinyl ester and polymerize (crosslink) with the vinyl ester.

Among the ethylenically unsaturated monomers contained in the first vinyl ester resin, the above-mentioned styrene-based monomers are preferred, and styrene is more preferred.

The content of the ethylenically unsaturated monomer in the first vinyl ester resin is, for example, 10 parts by mass or more, preferably 30 parts by mass or more, and, for example, 90 parts by mass or less, preferably 60 parts by mass or less, per 100 parts by mass of the total of the vinyl ester resin and the ethylenically unsaturated monomer.

The first acrylic syrup contains poly(meth)acrylate and/or acid-modified poly(meth)acrylate as a resin base and the above-mentioned ethylenically unsaturated monomer.

Poly(meth)acrylate is a polymerization product (polymer) of (meth)acrylate.

Examples of (meth)acrylates include mono(meth)acrylates having one (meth)acryloyl group and polyfunctional (meth)acrylates having two or more (meth)acryloyl groups.

Examples of mono(meth)acrylates include methyl (meth)acrylate, ethyl (meth)acrylate, isopropyl (meth)acrylate, n-butyl (meth)acrylate, t-butyl (meth)acrylate, isobutyl (meth)acrylate, 2-ethylhexyl (meth)acrylate, lauryl (meth)acrylate, alkyl (meth)acrylate (having 12 or 13 carbon atoms), tridecyl (meth)acrylate, stearyl (meth)acrylate, cyclohexyl (meth)acrylate, benzyl (meth)acrylate, isobornyl (meth)acrylate, glycidyl (meth)acrylate, tetrahydrofurfuryl (meth)acrylate, allyl (meth)acrylate, 2-ethylhexyl (meth)acrylate, lauryl (meth)acrylate, Examples of the mono(meth)acrylate include hydroxyethyl, hydroxypropyl (meth)acrylate, 2-methoxyethyl (meth)acrylate, 2-ethoxyethyl (meth)acrylate, dimethylaminoethyl (meth)acrylate, methyl chloride salt of dimethylaminoethyl (meth)acrylate, benzyl chloride salt of dimethylaminoethyl (meth)acrylate, diethylaminoethyl (meth)acrylate, trifluoroethyl (meth)acrylate, heptadecafluorodecyl (meth)acrylate, dicyclopentenyl (meth)acrylate, dicyclopentenyloxyethyl (meth)acrylate, dicyclopentanyl (meth)acrylate, and methoxypolyethylene glycol (meth)acrylate. In addition, such mono(meth)acrylates may be copolymerized with styrene.

Examples of polyfunctional (meth)acrylates include alkane glycol di(meth)acrylate and polyoxyalkylene di(meth)acrylate.

Examples of alkane glycol di(meth)acrylates include ethylene glycol di(meth)acrylate, propylene glycol di(meth)acrylate, and neopentyl glycol di(meth)acrylate.

Examples of polyoxyalkylene di(meth)acrylates include diethylene glycol di(meth)acrylate and triethylene glycol di(meth)acrylate.

Such (meth)acrylates can be used alone or in combination of two or more types.

The poly(meth)acrylate is prepared, for example, by polymerizing the above-mentioned (meth)acrylate under known reaction conditions.

Acid-modified poly(meth)acrylate is a (meth)acrylic acid ester copolymer resin that contains a side chain component represented by -OCO-X-COOH (wherein X represents an aromatic group, an alicyclic group, or an aliphatic group) in the side chain, and/or a component derived from (meth)acrylic acid.

The acid-modified poly(meth)acrylate is prepared, for example, by copolymerizing the addition reaction product obtained by the addition reaction of a hydroxyl group-containing vinyl monomer with the above-mentioned acid anhydride with the above-mentioned (meth)acrylate.

Examples of hydroxyl group-containing vinyl monomers include hydroxymethyl (meth)acrylate, hydroxyethyl (meth)acrylate, hydroxypropyl (meth)acrylate, and hydroxybutyl (meth)acrylate.

Also, the acid-modified poly(meth)acrylate can be prepared by addition reaction of the above-mentioned acid anhydride to the above-mentioned copolymer of the above-mentioned hydroxyl group-containing vinyl monomer and the above-mentioned (meth)acrylate.

In the first acrylic syrup, the ethylenically unsaturated monomer is capable of dissolving the above-mentioned poly(meth)acrylate and/or acid-modified poly(meth)acrylate, but is incapable of polymerizing with the above-mentioned poly(meth)acrylate and/or acid-modified poly(meth)acrylate.

Among the ethylenically unsaturated monomers contained in the first acrylic syrup, the above-mentioned (meth)acrylates are preferred, and methyl (meth)acrylate is more preferred.

The content of the ethylenically unsaturated monomer in the first acrylic syrup is, for example, 10 parts by mass or more, preferably 30 parts by mass or more, and for example, 90 parts by mass or less, preferably 80 parts by mass or less, per 100 parts by mass of the total of the poly(meth)acrylate, the acid-modified poly(meth)acrylate, and the ethylenically unsaturated monomer.

The first colorant imparts the desired color to the molded product, which will be described later. The first colorant is selected appropriately depending on the color and pattern required for the molded product.

The first colorant may be, for example, a toner. Examples of the toner include white toner, black toner, blue toner, green toner, yellow toner, gray toner, beige toner, pearl toner, and fluorescent toner.

The toner contains, for example, a powder pigment and a matrix resin. The powder pigment will be described in detail later. An example of the matrix resin is polyester.

The first colorant can be used alone or in combination of two or more types. By appropriately selecting the first colorant, the first thermosetting resin composition (the first resin material described below) can be adjusted to the desired color.

The content of the first colorant is, for example, 0.01 parts by mass or more, preferably 0.05 parts by mass or more, more preferably 0.1 parts by mass or more, and for example, 30 parts by mass or less, preferably 20 parts by mass or less, more preferably 10 parts by mass or less, relative to 100 parts by mass of the first thermosetting resin.

By adjusting the content ratio of the first colorant, the first thermosetting resin composition (the first resin material described below) can be adjusted to the desired color tone.

The first thermosetting resin composition may also contain other additives. Examples of additives include fillers, thickeners, shrinkage reducing agents, curing agents, polymerization inhibitors, and release agents.

Examples of fillers include inorganic fillers. Examples of inorganic fillers include oxides, hydroxides, carbonates, sulfates, silica, glass powder, hollow fillers, silicates, fluorides, phosphates, clay minerals, and milled fibers.

Examples of oxides include alumina and titania.

Examples of hydroxides include aluminum hydroxide and magnesium hydroxide.

An example of a carbonate is calcium carbonate.

An example of a sulfate is barium sulfate.

Examples of silica include crystalline silica, fused silica, fumed silica, and dry silica (aerosil).

Examples of hollow fillers include glass hollow spheres, silica hollow spheres, and alumina hollow spheres.

Examples of silicates include silica sand, diatomaceous earth, mica, clay, kaolin, and talc.

An example of a fluoride is fluorite.

An example of a phosphate is calcium phosphate.

An example of a clay mineral is smectite.

Milled fibers include, for example, long glass fibers milled to lengths of 30 to 300 μm.

Fillers can be used alone or in combination of two or more types.

Among the fillers, hydroxides, carbonates and glass powder are preferred, and aluminum hydroxide and glass powder are more preferred.

The filler content is, for example, 1 part by mass or more, preferably 10 parts by mass or more, more preferably 100 parts by mass or more, and for example, 600 parts by mass or less, preferably 400 parts by mass or less, per 100 parts by mass of the first thermosetting resin. Since aluminum hydroxide and magnesium hydroxide are flame retardant, they are contained in the railway vehicle components or flame retardant components in the range of 150 parts by mass to 600 parts by mass.

Thickeners include, for example, alkaline earth metal oxides, alkaline earth metal hydroxides, and polyisocyanates.

An example of an alkaline earth metal oxide is magnesium oxide.

Examples of alkaline earth metal hydroxides include magnesium hydroxide and calcium hydroxide.

Examples of polyisocyanates include aromatic polyisocyanates, alicyclic polyisocyanates, araliphatic polyisocyanates, aliphatic polyisocyanates, and modified products thereof.

Examples of aromatic polyisocyanates include tolylene diisocyanate (TDI) and 4,4'-diphenylmethane diisocyanate (MDI).

Examples of alicyclic polyisocyanates include hydrogenated xylylene diisocyanate (H ₆ XDI), isophorone diisocyanate (IPDI), hydrogenated 4,4'-diphenylmethane diisocyanate (H ₁₂ MDI), and norbornanemethane diisocyanate (NBDI).

An example of an aromatic aliphatic polyisocyanate is xylylene diisocyanate (XDI).

An example of an aliphatic polyisocyanate is hexamethylene diisocyanate (HDI).

Among the thickeners, alkaline earth metal oxides are preferred, and magnesium oxide is more preferred.

Thickeners can be used alone or in combination of two or more types.

The content of the thickener is, for example, 0.1 parts by mass or more and, for example, 4 parts by mass or less, preferably 2 parts by mass or less, per 100 parts by mass of the first thermosetting resin.

Examples of low shrinkage agents include polyvinyl acetate, poly(meth)acrylate resins, cellulose ester resins, polystyrene, crosslinked polystyrene, polyethylene, polyvinyl acetate-polystyrene block copolymers, SBS (rubber), SEPS (rubber), and saturated polyester resins.

Among the low shrinkage agents, preferred are polystyrene, cross-linked polystyrene, polyethylene, and polyvinyl acetate-polystyrene block copolymers.

The shrinkage reducing agents can be used alone or in combination of two or more types.

The content of the low shrinkage agent is, for example, 1 part by mass or more, preferably 5 parts by mass or more, and, for example, 40 parts by mass or less, preferably 25 parts by mass or less, per 100 parts by mass of the first thermosetting resin.

Examples of the curing agent (polymerization initiator) include peroxides. Examples of peroxides include benzoyl peroxide, t-butylperoxyisopropyl monocarbonate, t-amylperoxyisopropyl monocarbonate, t-hexylperoxyisopropyl monocarbonate, 1,1-bis(t-butylperoxy)cyclohexane, t-butylperoxy-2-ethylhexanoate, amylperoxy-2-ethylhexanoate, 2-ethylhexylperoxy-2-ethylhexanoate, t-butylperoxybenzoate, t-hexylperoxybenzoate, and t-hexylperoxyacetate.

The hardeners can be used alone or in combination of two or more types.

Among the curing agents, preferred are benzoyl peroxide, t-butylperoxyisopropyl monocarbonate, and t-amylperoxyisopropyl monocarbonate.

The content of the curing agent is, for example, 0.5 parts by mass or more, preferably 0.8 parts by mass or more, and, for example, 10 parts by mass or less, preferably 3 parts by mass or less, per 100 parts by mass of the first thermosetting resin.

Examples of polymerization inhibitors include hydroquinone compounds, benzoquinone compounds, naphthoquinone compounds, catechol compounds, aromatic amine compounds, and N-oxyl compounds.

Examples of hydroquinone compounds include hydroquinone, methylhydroquinone, 2-t-butylhydroquinone, 2,5-di-t-butylhydroquinone, trimethylhydroquinone, and N-methoxyhydroquinone.

Examples of benzoquinone compounds include parabenzoquinone and N2,5-di-t-butylbenzoquinone.

An example of a naphthoquinone compound is naphthoquinone.

An example of a catechol compound is p-t-butylcatechol.

An example of an aromatic amine compound is phenothiazine.

Examples of N-oxyl compounds include 1-oxyl-2,2,6,6-tetramethylpiperidine, 1-oxyl-2,2,6,6-tetramethylpiperidin-4-ol, 4-hydroxy-2,2,6,6-tetrapiperidine-1-oxyl, 4-methoxy-2,2,6,6-tetramethylpiperidine-1-oxyl, 1-oxyl-2,2,6,6-tetramethylpiperidin-4-yl-acetate, 1-oxyl-2,2,6,6-tetramethylpiperidin-4-yl-2-ethylhexanoate, 1 -oxyl-2,2,6,6-tetramethylpiperidin-4-yl-stearate, 1-oxyl-2,2,6,6-tetramethylpiperidin-4-yl-4-t-butylbenzoate, bis(1-oxyl-2,2,6,6-tetramethylpiperidin-4-yl)succinate, bis(1-oxyl-2,2,6,6-tetramethylpiperidin-4-yl)adipate, bis(1-oxyl-2,2,6,6-tetramethylpiperidin-4-yl)sebacate, bis(1-oxyl-2,2, N,N'-bis(1-oxyl-2,2,6,6-tetramethylpiperidin-4-yl) n-butyl malonate, bis(1-oxyl-2,2,6,6-tetramethylpiperidin-4-yl) phthalate, bis(1-oxyl-2,2,6,6-tetramethylpiperidin-4-yl) isophthalate, bis(1-oxyl-2,2,6,6-tetramethylpiperidin-4-yl) terephthalate, bis(1-oxyl-2,2,6,6-tetramethylpiperidin-4-yl) hexahydroterephthalate, N,N'-bis(1-oxyl-2 ,2,6,6-tetramethylpiperidin-4-yl)adipamide, N-bis(1-oxyl-2,2,6,6-tetramethylpiperidin-4-yl)caprolactam, N-bis(1-oxyl-2,2,6,6-tetramethylpiperidin-4-yl)dodecylsuccinimide, 2,4,6-tris-[N-butyl-N-(1-oxyl-2,2,6,6-tetramethylpiperidin-4-yl)]-s-triazine, and 1-oxyl-2,2,6,6-tetramethylpiperidin-4-one.

Among the polymerization inhibitors, hydroquinone compounds, benzoquinone compounds, and N-oxyl compounds are preferred, and hydroquinone and parabenzoquinone are more preferred.

Polymerization inhibitors can be used alone or in combination of two or more types.

The content of the polymerization inhibitor is, for example, 0.005 parts by mass or more, preferably 0.01 parts by mass or more, and, for example, 0.5 parts by mass or less, preferably 0.20 parts by mass or less, per 100 parts by mass of the first thermosetting resin.

Examples of release agents (internal release agents) include fatty acids, fatty acid metal salts, paraffin, liquid wax, fluoropolymers, and silicone-based polymers.

Fatty acids include, for example, stearic acid and lauric acid.

Examples of fatty acid metal salts include zinc stearate and calcium stearate.

Among the releasing agents, fatty acids and fatty acid metal salts are preferred, and stearic acid and zinc stearate are more preferred.

Release agents can be used alone or in combination of two or more types.

The content of the release agent is, for example, 1 part by mass or more, preferably 3 parts by mass or more, and, for example, 10 parts by mass or less, per 100 parts by mass of the first thermosetting resin.

The first thermosetting resin composition may further contain other additives, such as a wetting and dispersing agent, a separation inhibitor, a flame retardant, a conductive agent, and an ultraviolet absorbing agent, in appropriate proportions, as necessary.

Examples of reinforcing fibers include inorganic fibers, organic fibers, and natural fibers.

Examples of inorganic fibers include glass fibers, carbon fibers, metal fibers, and ceramic fibers.

Examples of organic fibers include polyvinyl alcohol-based fibers, polyester-based fibers, polyamide-based fibers, fluororesin-based fibers, and phenol-based fibers.

Natural fibers include, for example, hemp and kenaf.

Among the reinforcing fibers, inorganic fibers are preferred, carbon fibers and glass fibers are more preferred, and glass fibers are even more preferred.

The reinforcing fibers can be used alone or in combination of two or more types.

Examples of the shape of the reinforcing fibers include cloth, chopped strand mat, preformable mat, continuous strand mat, surfacing mat and other mat shapes, strand shape, chopped strand shape, roving shape, nonwoven fabric shape, paper shape, etc.

Among the shapes of the reinforcing fibers, roving is preferred.

The dimensions and mixing ratio of these reinforcing fibers are changed as appropriate depending on the form of the first resin molding compound.

Examples of the first resin molding compound include sheet molding compound (hereinafter referred to as SMC), thick molding compound (hereinafter referred to as TMC), and bulk molding compound (hereinafter referred to as BMC).

The SMC has, for example, a sheet shape. The SMC has, for example, a rectangular shape when viewed in the thickness direction. The thickness of the SMC is, for example, 0.5 mm or more and 6.0 mm or less. The dimension of the SMC in a direction perpendicular to the thickness direction is, for example, 50 cm or more and 200 cm or less. The mass of the SMC is appropriately determined to suit the mass and thickness of the molded product.

In addition, multiple SMCs can be stacked in the thickness direction to form a first resin molding compound. In this case, the mass of the first resin molding compound is appropriately determined to suit the mass and thickness of the molded product.

Such an SMC is prepared, for example, by mixing the first thermosetting resin described above, the first colorant described above, and, if necessary, additives other than the thickener, adding the thickener described above to the mixture, and then adding the reinforcing fibers described above using a known SMC impregnation machine.

When the first resin molding compound is SMC, the length of the reinforcing fibers is, for example, 10 mm or more, preferably 12 mm or more, and, for example, 60 mm or less, preferably 30 mm or less.

When the first resin molding compound is SMC, the mixing ratio of the reinforcing fibers is, for example, 10 parts by mass or more, preferably 20 parts by mass or more, and, for example, 200 parts by mass or less, preferably 150 parts by mass or less, per 100 parts by mass of the first thermosetting resin.

The TMC has, for example, a block or sheet shape. When the TMC has a sheet shape, the TMC has, for example, a rectangular shape when viewed in the thickness direction. The thickness of the TMC is, for example, 2.0 mm or more and 30.0 mm or less. The dimension of the TMC in a direction perpendicular to the thickness direction is, for example, 50 cm or more and 200 cm or less. The mass of the TMC is appropriately determined to suit the mass and thickness of the molded product.

The TMC is prepared, for example, by mixing the first thermosetting resin described above, the first colorant described above, and, if necessary, additives other than the thickener, adding the thickener described above to the mixture, and then adding the reinforcing fibers described above using a known TMC impregnation machine.

When the first resin molding compound is TMC, the length of the reinforcing fibers is, for example, 3 mm or more, preferably 5 mm or more, and, for example, 60 mm or less, preferably 30 mm or less.

When the first resin molding compound is TMC, the mixing ratio of the reinforcing fibers is, for example, 10 parts by mass or more, preferably 20 parts by mass or more, and, for example, 200 parts by mass or less, preferably 150 parts by mass or less, per 100 parts by mass of the first thermosetting resin.

The BMC has a block shape, for example, a cylinder or a rectangular parallelepiped. The block unit of the BMC is, for example, 0.1 kg or more and 30 kg or less.

The BMC is prepared, for example, by mixing the first thermosetting resin described above, the first colorant described above, and, if necessary, additives other than the thickener, adding the thickener described above to the mixture, then adding reinforcing fibers, and mixing the mixture in a known BMC kneader.

When the first resin molding compound is BMC, the length of the reinforcing fibers is, for example, 1 mm or more, preferably 2 mm or more, and, for example, 30 mm or less, preferably 25 mm or less.

When the first resin molding compound is BMC, the mixing ratio of the reinforcing fibers is, for example, 1 part by mass or more, preferably 5 parts by mass or more, for example, 100 parts by mass or less, preferably 60 parts by mass or less, per 100 parts by mass of the first thermosetting resin.

Among such first resin molding compounds, BMC is preferred.

The first resin molding compound is prepared in this manner. Note that the manufacturing method of the molding compound described above does not limit the scope of the present invention.

Next, the first resin material having a small piece shape is cut out from the first resin molding compound by a known cutting method. For example, an extruder and a cutter are combined to prepare the first resin material having a small piece shape. Specifically, the extruder extrudes the first resin molding compound in a predetermined shape. Examples of the predetermined shape include a cylindrical shape and a rectangular column shape. Next, the cutter cuts the extruded first resin molding compound to a predetermined length. Note that the above-mentioned molding compound cutting method does not limit the present invention.

Therefore, the first resin material having a small particle shape contains the first thermosetting resin composition described above and the reinforcing fibers described above.

This process prepares the first resin material in the form of small pieces.

The first resin material has a small piece shape. Specific examples of the shape of the first resin material include a cube (dice shape), a rectangular parallelepiped, a cylinder, a prism, a sphere, and a random shape.

Among the shapes of the first resin material, preferred are a cube (dice), a rectangular solid, and a cylinder.

The maximum dimension of the first resin material is, for example, 1 mm or more, preferably 2 mm or more, and, for example, 150 mm or less, preferably 50 mm or less, more preferably 10 mm or less.

If the maximum dimension of the first resin material is equal to or greater than the lower limit, the first resin material can be easily and smoothly cut out of the first resin molding compound. If the maximum dimension of the first resin material is equal to or greater than the lower limit, a complex marble-like pattern can be imparted to the molded product described below.

The shape and dimensions of the first resin material are selected appropriately depending on the pattern required for the molded product, which will be described later.

1-2. Mixed Material Preparation Step Next, the first resin material and the powder pigment having a maximum dimension of 1000 μm or less are mixed to prepare a mixed material (preparation step).

The powder pigment has a powder shape. The maximum dimension of the powder pigment is, for example, 10 nm or more, preferably 30 nm or more, and 1000 μm or less, preferably 500 μm or less.

If the maximum dimension of the powder pigment is equal to or greater than the above lower limit, a transparent marble pattern can be imparted to the molded product described below. If the maximum dimension of the powder pigment is equal to or less than the above upper limit, a complex marble pattern can be stably imparted to the molded product described below.

Powder pigments include, for example, inorganic pigments and organic pigments.

Examples of inorganic pigments include white inorganic pigments, black inorganic pigments, blue inorganic pigments, red inorganic pigments, green inorganic pigments, yellow inorganic pigments, pearl inorganic pigments, fluorescent inorganic pigments, and phosphorescent inorganic pigments.

Examples of white inorganic pigments include titanium white and zinc sulfide.

Examples of black inorganic pigments include carbon black, iron oxide, ferrite, and chromium oxide.

Examples of blue inorganic pigments include cobalt blue and ferric ferrocyanide.

Examples of red inorganic pigments include red iron oxide and cobalt pink.

Examples of green inorganic pigments include cobalt green and chromium oxide green.

Examples of yellow inorganic pigments include nickel titanium yellow and yellow iron oxide.

Examples of pearlescent inorganic pigments include mica-based pearlescent pigments, glass flake-based pearlescent pigments, alumina flake-based pearlescent pigments, silica flake-based pearlescent pigments, bismuth-based pearlescent pigments, pearlescent pigments in which metal is vapor-deposited onto a film, and metal powder-based pigments.

Examples of mica-based pearl pigments include muscovite coated with titanium dioxide and basic lead carbonate.

Examples of glass flake pearl pigments include glass flake pigments coated with gold, silver, nickel, titanium oxide, iron oxide, etc.

Examples of alumina flake-based pearl pigments include alumina flake-based pigments coated with gold, silver, nickel, titanium oxide, iron oxide, etc.

Examples of silica flake-based pearl pigments include silica flake-based pigments coated with gold, silver, nickel, titanium oxide, iron oxide, etc.

An example of a bismuth-based pearl pigment is a bismuth oxychloride-based pigment.

Metal powder pigments include, for example, gold, silver, aluminum, nickel, and iron oxide.

In addition, a surface coating such as a silane coupling agent may be added to the surface of these pearl pigments to improve adhesion to the resin and wear resistance, and this is not a limitation of the present invention.

Fluorescent inorganic pigments include, for example, pigments obtained by calcining a crystal of oxides, sulfides, silicates, etc. of Ca, Ba, Mg, Zn, Cd, etc. as the main component, and adding metal elements such as Mn, Zn, Ag, Cu, Sb, Pb, etc. or rare earth elements such as lanthanides as an activator.

Examples of phosphorescent inorganic pigments include zinc sulfide (ZnS-based) pigments and strontium aluminate (SrnAlnOn-based) pigments.

Organic pigments are classified according to their chemical structure, and pigments belonging to the same classification may have different colors. Examples of classifications of organic pigments include phthalocyanine, azo lake, monoazo, disazo, condensed azo, chelate azo, quinacridone, dioxazine, isoindolinone, thioindigo, perylene, quinophthalone, anthraquinone, carmine, naphthol, pyrazolone, and dibromoanthrone.

When organic pigments are classified by color, examples of organic pigments include black organic pigments, blue organic pigments, red organic pigments, green organic pigments, yellow organic pigments, orange organic pigments, purple organic pigments, and brown organic pigments. Organic pigments are also classified by assigning color index numbers (C.I. Pigment) in the Color Index (C.I.). C.I is a database jointly operated by the Society of Dyers and Colourists and the American Association of Textile Chemists and Colorists.

Examples of C.I. Pigment black organic pigments include Black 1 and 7.

Examples of blue organic pigments include C.I. Pigment Blue 1, 2, 15, 15:3, 15:4, 15:6, 22, 60, 64, and 66.

Examples of C.I. Pigment red organic pigments include Red 9, 97, 105, 122, 123, 149, 150, 155, 168, 171, 175, 176, 177, 180, 192, 209, 215, 216, 217, 220, 223, 224, 226, 227, 228, and 240.

Examples of C.I. Pigment green organic pigments include Green 7, 36, and 37.

Examples of C.I. Pigment yellow organic pigments include Yellow 11, 20, 24, 31, 53, 83, 86, 93, 99, 108, 109, 110, 117, 125, 129, 137, 138, 139, 147, 148, 150, 151, 153, 154, 166, 167, and 168.

Examples of orange organic pigments include C.I. Pigment Orange 36, 38, 43, 51, 55, 59, and 61.

Examples of C.I. Pigment purple organic pigments include Violet 19, 23, 29, 30, 32, 37, 39, 40, and 50.

Examples of brown pigments in C.I. Pigment include Brown 23, 25, 26, and 28.

The powder pigments can be used alone or in combination of two or more kinds. The powder pigment is appropriately selected according to the color and pattern required for the molded product. Among the powder pigments, inorganic pigments are preferable, but the present invention is not limited by the type of powder pigment.

More preferably, the powder pigment has a color and/or tone different from that of the first resin material. It is particularly preferable that the powder pigment has a color and/or tone different from that of the first colorant contained in the first resin material. This makes it possible to more stably impart a natural marble-like pattern to the molded product described below.

The color tone refers to the intensity and shading of the color, and the color tone depending on whether or not a pattern material is used. Examples of pattern materials include scale-like materials, glitter materials, and the pearl pigments mentioned above.

Examples of combinations of the first colorant and the powder pigment include a combination of green toner and a white inorganic pigment, a combination of white toner and a red inorganic pigment, a combination of white toner and a pearl inorganic pigment, a combination of white toner and a white inorganic pigment, a combination of red toner and a white inorganic pigment, and a combination of gray toner and a white inorganic pigment.

The first resin material and the powder pigment are then, for example, dry mixed. As a result, the powder pigment is applied to the first resin material. In other words, the powder pigment adheres to the surface of the first resin material. In this way, a mixed material of the first resin material and the powder pigment is prepared.

The mixing ratio of the powder pigment is, for example, 0.0001 parts by mass or more, preferably 0.001 parts by mass or more, more preferably 0.01 parts by mass or more, particularly preferably 0.10 parts by mass or more, and 10 parts by mass or less, preferably 1.0 parts by mass or less, per 100 parts by mass of the first resin material.

If the mixing ratio of the powder pigment is within the above range, the natural marble pattern can be imparted more reliably to the molded product described below.

1-3. Molding process of the mixed material Next, the mixed material is molded (molding process).

Methods for molding mixed materials include, for example, press molding and injection molding. Of the methods for molding mixed materials, press molding is preferred.

In more detail, after placing the mixed material in a first mold, the second mold is moved toward the first mold to sandwich the mixed material between the first and second molds, and the resin mixture is cured and molded under predetermined molding conditions. The molding conditions include molding pressure, temperature, and time.

The molding pressure is, for example, 1 MPa or more, preferably 5 MPa or more, and, for example, 30 MPa or less, preferably 15 MPa or less.

The molding temperature of the first mold is, for example, 80°C or more, preferably 125°C or more, and, for example, 200°C or less, preferably 135°C or less. The molding temperature of the second mold is, for example, 80°C or more, preferably 140°C or more, and, for example, 200°C or less, preferably 150°C or less.

The molding time is, for example, 1 minute or more, preferably 3 minutes or more, and, for example, 30 minutes or less, preferably 10 minutes or less.

During this molding process, the small pieces of the first resin material are crushed, and the first resin material and the powder material are mixed together to form a marbled pattern. The first resin material then hardens, forming a natural marbled pattern that is similar to that of natural marble.

This process produces a molded product with a natural marble look and the desired shape.

When BMC is used as a molding material, it has inferior strength at the same thickness compared to molded products that use SMC or TMC. For this reason, there is a method of simultaneously molding a glass mat to reinforce molded products that use BMC, or a method of spraying glass fiber and resin on the back side of the molded product to reinforce it.

The molded article contains a cured product of the first thermosetting resin composition described above and the reinforcing fibers described above.

Such molded products are suitable for use in a variety of industrial products, and are particularly suitable for use in products that require excellent design (highly designed products).

Examples of highly sophisticated products include plumbing products, building materials, railroad vehicle components, lighting components, and automotive materials.

Examples of plumbing products include bathtubs, washbasin counters, kitchen counters, kitchen sinks, and bathroom unit components (e.g., bathroom unit washing areas, washbasin counters, floors, ceilings, walls, and bathtubs with washing areas).

Examples of building materials include wall materials, tile materials, skylight materials, and flooring materials.

Examples of railway vehicle components include lighting cover parts, table parts, flame-retardant parts, window frame parts, and walls.

An example of an illumination component is a lighting cover.

Automotive materials include, for example, interior parts.

Further uses of the molded products include, for example, elevator ceilings and walls, stained glass replacement materials, mobile electronic media (e.g., personal computers, mobile phones) frames, design parts for electrical appliances (e.g., covers, televisions), and flame-retardant materials (e.g., breaker boxes).

1-4. Effects and Effects In the above-described method for producing a marble-patterned molded product, the first resin material having small flakes and the powder pigment are mixed together, and then the mixed material is molded.

Therefore, when the mixed material is molded, the first resin material, which has a small flake shape, and the powder pigment are mixed together to form a marbled look. As a result, a natural marbled look similar to that of natural marble can be achieved in the molded product, even with a simple method.

The powder pigment preferably has a different color and/or tone from the first resin material. This allows the molded product to have a complex marble-like pattern.

The first resin material is prepared by cutting it out from the first resin molding compound. This allows the first resin material to be smoothly prepared in a desired shape and size.

Second Embodiment
Next, a second embodiment of the present invention will be described. Note that detailed descriptions of steps similar to those of the first embodiment will be omitted.

In the second embodiment, a second resin material is further prepared, and the first resin material, the powder pigment, and the second resin material are mixed to prepare a mixed material. In other words, the method for manufacturing a marble-like molded product further includes a step of preparing a second resin material, and in the step of preparing the mixed material, the first resin material, the powder pigment, and the second resin material are mixed.

2-1. Step of Preparing Second Resin Material The second resin material has a different color and/or color tone from the first resin material, and is in the form of small pieces or liquid.

2-1-1. Second resin material having a small flake shape First, the second resin material having a small flake shape will be described.

The second resin material, which has a flake shape, is similar to the first resin material, except that it has a different color and/or hue from the first resin material.

To prepare the second resin material having a small particle shape, for example, first prepare the second resin molding compound in the same manner as in the molding compound preparation process described above.

The second resin molding compound is similar to the first resin molding compound except for the color and/or shade.

Therefore, the second resin molding compound is the same as the first resin molding compound, except that the first colorant is changed to the second colorant. In other words, the second resin molding compound contains the second thermosetting resin composition and the reinforcing fibers described above. The second thermosetting resin composition contains the first thermosetting resin and the second colorant described above.

The second colorant has, for example, a different color than the first colorant. The second colorant preferably has a different color and/or hue than the first colorant and the powder pigment. An example of the second colorant is a toner similar to the first colorant described above.

The second colorant can be used alone or in combination of two or more types.

By appropriately selecting the second colorant, the second resin material can be adjusted to a desired color so that it differs from the first resin material.

The content of the second colorant is, for example, 0.5 parts by mass or more, preferably 3 parts by mass or more, and, for example, 15 parts by mass or less, preferably 10 parts by mass or less, per 100 parts by mass of the first thermosetting resin contained in the second thermosetting resin composition.

By adjusting the content ratio of the second colorant, the second resin material can be adjusted to a desired color tone so that the color tone is different from that of the first resin material. Note that the second colorant and the content ratio of the second colorant described above do not limit the present invention.

Next, small pieces of the second resin material are cut out from the second resin molding compound using the method described above.

This results in the preparation of a second resin material having a small particle shape. The second resin material having a small particle shape contains the second thermosetting resin composition described above and the reinforcing fibers described above.

The size of the second resin material may be the same as or different from the size of the first resin material.

The maximum dimension of the second resin material is, for example, 1 time or more, preferably 5 times or more, and, for example, 500 times or less, preferably 100 times or less, and more preferably 50 times or less, of the maximum dimension of each of the first resin materials described above.

The maximum dimension of the second resin material is, for example, 1 mm or more, preferably 5 mm or more, more preferably more than 10 mm, and, for example, 500 mm or less, preferably 100 mm or less, more preferably 50 mm or less.

If the first resin material and the second resin material are different sizes, it is possible to reliably impart a marble-like pattern similar to that of natural marble to the molded product.

2-1-2. Second Resin Material Having a Liquid State Next, the second resin material having a liquid state will be described.

The second resin material, which has a liquid state, is in a liquid state with fluidity at room temperature (23°C).

The second resin material having a liquid form includes, for example, a second thermosetting resin and the second colorant described above.

The second thermosetting resin is similar to the first thermosetting resin except for the content of the ethylenically unsaturated monomer. The content of the ethylenically unsaturated monomer in the second thermosetting resin is greater than the content of the ethylenically unsaturated monomer in the first thermosetting resin. The content of the ethylenically unsaturated monomer in the second thermosetting resin is, for example, 10% by mass or more, preferably 20% by mass or more, more preferably 30% by mass or more, even more preferably 40% by mass or more, particularly preferably 65% by mass or more, and, for example, 95% by mass or less, preferably 80% by mass or less.

Examples of the second thermosetting resin include a second unsaturated polyester resin, a second vinyl ester resin, and a second acrylic syrup. The second thermosetting resin can be used alone or in combination of two or more types.

In other words, the second thermosetting resin includes at least one selected from the group consisting of a second unsaturated polyester resin, a second vinyl ester resin, and a second acrylic syrup.

The second unsaturated polyester resin is the same as the first unsaturated polyester resin described above, except for the content ratio of the ethylenically unsaturated monomer.

The content of the ethylenically unsaturated monomer in the second unsaturated polyester resin is greater than the content of the ethylenically unsaturated monomer in the first unsaturated polyester resin. The content of the ethylenically unsaturated monomer in the second unsaturated polyester resin is, for example, 10 parts by mass or more, preferably 20 parts by mass or more, more preferably 30 parts by mass or more, even more preferably 40 parts by mass or more, particularly preferably 65 parts by mass or more, and, for example, 95 parts by mass or less, preferably 80 parts by mass or less, per 100 parts by mass of the total of the unsaturated polyester and the ethylenically unsaturated monomer.

The second vinyl ester resin is the same as the first vinyl ester resin described above, except for the content of the ethylenically unsaturated monomer.

The content of the ethylenically unsaturated monomer in the second vinyl ester resin is greater than the content of the ethylenically unsaturated monomer in the first vinyl ester resin. The content of the ethylenically unsaturated monomer in the second vinyl ester resin is, for example, 10 parts by mass or more, preferably 20 parts by mass or more, more preferably 30 parts by mass or more, even more preferably 40 parts by mass or more, particularly preferably 65 parts by mass or more, and for example, 95 parts by mass or less, preferably 80 parts by mass or less, per 100 parts by mass of the total of the vinyl ester resin and the ethylenically unsaturated monomer.

The second acrylic syrup is the same as the first acrylic syrup described above, except for the content ratio of the ethylenically unsaturated monomer.

The content of the ethylenically unsaturated monomer in the second acrylic syrup is greater than the content of the ethylenically unsaturated monomer in the first acrylic syrup. The content of the ethylenically unsaturated monomer in the second acrylic syrup is, for example, 10 parts by mass or more, preferably 20 parts by mass or more, more preferably 30 parts by mass or more, even more preferably 40 parts by mass or more, and for example, 95 parts by mass or less, preferably 85 parts by mass or less, more preferably 80 parts by mass or less, per 100 parts by mass of the total of the poly(meth)acrylate, the acid-modified poly(meth)acrylate, and the ethylenically unsaturated monomer.

Preferred combinations of the first thermosetting resin and the second thermosetting resin include a combination of a first unsaturated polyester resin and a second unsaturated polyester resin, a combination of a first vinyl ester resin and a second vinyl ester resin, and a combination of a first acrylic syrup and a second acrylic syrup.

The content of the second colorant is, for example, 0.5 parts by mass or more, preferably 3 parts by mass or more, for example, 15 parts by mass or less, preferably 10 parts by mass or less, per 100 parts by mass of the second thermosetting resin.

By adjusting the content ratio of the second colorant, the second resin material can be adjusted to a desired color tone so that the color tone is different from that of the first resin material. Note that the second colorant and the content ratio of the second colorant described above do not limit the present invention.

The second resin material having a liquid state preferably does not contain the reinforcing fibers described above. Therefore, the viscosity of the second resin material having a liquid state can be stably adjusted to the following range.

The viscosity (at 25°C) of the second resin material having a liquid state is, for example, 1 mPa·s or more, preferably 2 mPa·s or more, and, for example, 30,000 mPa·s or less, preferably 10,000 mPa·s or less. The viscosity (at 25°C) of the second resin material having a liquid state can be measured, for example, by a B-type viscometer (same below).

The second resin material having a liquid state is prepared, for example, by mixing the second thermosetting resin described above, the second colorant described above, and, if necessary, other additives.

This prepares the second resin material, which has a liquid state.

The second resin material may contain other additives. Examples of additives include the filler, the hardener, the polymerization inhibitor, and the release agent.

When the second resin material having a small particle shape contains an additive, the range of the additive content is the same as the range of the additive content in the first resin material.

When the second resin material having a liquid state contains an additive, the range of the additive content is different from the range of the additive content in the first resin material.

In detail, the content of the filler is, for example, 1 part by mass or more, preferably 10 parts by mass or more, more preferably 50 parts by mass or more, and for example, 300 parts by mass or less, preferably 200 parts by mass or less, more preferably 150 parts by mass or less, and even more preferably less than 100 parts by mass, relative to 100 parts by mass of the second thermosetting resin.

The content of the curing agent is, for example, 0.1 parts by mass or more, preferably 0.5 parts by mass or more, and, for example, 10 parts by mass or less, preferably 3 parts by mass or less, per 100 parts by mass of the second thermosetting resin.

The content of the polymerization inhibitor is, for example, 0.0001 parts by mass or more, preferably 0.005 parts by mass or more, and for example, 0.3 parts by mass or less, preferably 0.20 parts by mass or less, more preferably 0.030 parts by mass or less, and even more preferably 0.010 parts by mass or less, relative to 100 parts by mass of the second thermosetting resin. The second resin material does not have to contain a polymerization inhibitor.

The content of the release agent is, for example, 0.3 parts by mass or more, preferably 0.5 parts by mass or more, and, for example, 10 parts by mass or less, per 100 parts by mass of the second thermosetting resin.

Furthermore, the second resin material may contain, as other additives, at least one selected from the group consisting of a thickener, a shrinkage reducing agent, a wetting and dispersing agent, a separation prevention agent, a flame retardant, a conductive agent, and an ultraviolet absorbing agent in an appropriate ratio, as necessary.

2-2. Preparation of Mixed Material Then, in addition to the first resin material and the powder material, a second resin material having a small particle or liquid form is mixed to prepare a mixed material.

When the second resin material has a small particle shape, for example, the first resin material described above, the powder material described above, and the second resin material having a small particle shape are dry mixed.

The mixing ratio of the second resin material having a small particle shape is, for example, 1 part by mass or more, preferably 10 parts by mass or more, and, for example, 5000 parts by mass or less, preferably 1000 parts by mass or less, per 100 parts by mass of the first resin material.

When the second resin material is liquid, for example, the above-mentioned first resin material and powder material are mixed, and then the mixture is immersed in the second resin material having a liquid state. Alternatively, the second resin material having a liquid state may be sprayed onto the mixture of the first resin material and the powder material. Alternatively, the first resin material and the second resin material may be mixed, and then the mixture may be mixed with the powder material.

The mixing ratio of the second resin material having a liquid form is, for example, 0.05 parts by mass or more, preferably 0.05 parts by mass or more, and, for example, 50 parts by mass or less, preferably 10 parts by mass or less, more preferably 5 parts by mass or less, per 100 parts by mass of the first resin material.

The mixed material is then cured and molded under the molding conditions described above (molding process).

As a result, the flake-like first resin material, the powder material, and the flake-like or liquid second resin material are mixed together to form a marbled effect. The first and second resin materials are then cured, forming a complex marbled effect pattern.

This process produces a molded product with a natural marble look and the desired shape.

This second embodiment can achieve the same effects as the first embodiment.

Third Embodiment
Next, a third embodiment of the present invention will be described. Note that detailed descriptions of steps similar to those of the first and second embodiments will be omitted.

In the third embodiment, a third resin material is further prepared, and the first resin material, the powder pigment, the second resin material, and the third resin material are mixed to prepare a mixed material. In other words, the method for manufacturing a marble-like molded product further includes a step of preparing a third resin material, and in the step of preparing the mixed material, the first resin material, the powder pigment, the second resin material, and the third resin material are mixed.

3-1. Step of Preparing Third Resin Material The third resin material has a color and/or a color tone different from those of the first resin material and the second resin material, and is in the form of small pieces or a liquid.

The third resin material is similar to the second resin material except that it has a different color and/or hue from the first resin material and the second resin material. In other words, the third resin material having a platelet shape is similar to the second resin material having a platelet shape except that it has a different color and/or hue. The third resin material having a liquid shape is similar to the second resin material having a liquid shape except that it has a different color and/or hue.

The third resin material includes a third colorant.

The third colorant has, for example, a color different from the first colorant and the second colorant. The third colorant preferably has a color and/or tone different from the first colorant, the second colorant, and the powder pigment. An example of the third colorant is a toner similar to the first colorant described above.

The third colorant can be used alone or in combination of two or more types.

By appropriately selecting the third colorant, the third resin material can be adjusted to a desired color so that it is different in color from the first resin material and the second resin material.

3-2. Preparation of mixed material Then, in addition to the first resin material, the powder material, and the second resin material, a third resin material having a small piece or liquid form is mixed to prepare a mixed material. The third resin material is preferably in a small piece form.

When the second resin material and the third resin material are in a small particle shape, for example, the first resin material described above, the powder material described above, the second resin material described above, and the third resin material in a small particle shape are dry mixed.

When the second resin material is liquid and the third resin material is flake-like, for example, the first resin material and the powder material described above are mixed. Also, the third resin material having a flake-like shape is mixed with the second resin material having a liquid shape. For example, the third resin material having a flake-like shape is immersed in the second resin material having a liquid shape. The second resin material having a liquid shape may be sprayed onto the third resin material having a flake-like shape. Then, the mixture of the first resin material and the powder material is mixed with the mixture of the second resin material and the third resin material.

The range of the mixing ratio of the third resin material having a small particle shape is, for example, the same as the above-mentioned range of the mixing ratio of the second resin material having a small particle shape. The range of the mixing ratio of the third resin material having a liquid shape is, for example, the same as the above-mentioned range of the mixing ratio of the second resin material having a liquid shape.

The mixed material is then cured and molded under the molding conditions described above (molding process).

As a result, the first resin material having a flake shape, the powder material, the second resin material having a flake shape or a liquid shape, and the third resin material having a flake shape or a liquid shape are mixed together to form a more complex marble pattern. The first resin material, the second resin material, and the third resin material are then cured, forming a more complex marble pattern.

This process produces a molded product with a natural marble look and the desired shape.

This third embodiment can achieve the same effects as the first embodiment.

Fourth Embodiment
Next, a fourth embodiment of the present invention will be described. Note that detailed descriptions of steps similar to those of the first to third embodiments will be omitted.

In the fourth embodiment, a fourth resin material is further prepared, and the first resin material, the powder pigment, the second resin material, the third resin material, and the fourth resin material are mixed to prepare a mixed material. In other words, the manufacturing method for a marble-like molded product further includes a step of preparing a fourth resin material, and in the step of preparing the mixed material, the first resin material, the powder pigment, the second resin material, the third resin material, and the fourth resin material are mixed.

4-1. Step of Preparing Fourth Resin Material The fourth resin material has a color and/or a color tone different from those of the first resin material, the second resin material, and the third resin material, and is in the form of small pieces or liquid.

The fourth resin material is similar to the second resin material except that it has a different color and/or hue from the first resin material, the second resin material, and the third resin material. In other words, the fourth resin material having a platelet shape is similar to the second resin material having a platelet shape except that it has a different color and/or hue. The fourth resin material having a liquid shape is similar to the fourth resin material having a liquid shape except that it has a different color and/or hue.

The fourth resin material includes a fourth colorant.

The fourth colorant has, for example, a color different from the first colorant, the second colorant, and the third colorant. The fourth colorant preferably has a color and/or tone different from the first colorant, the second colorant, the third colorant, and the powder pigment. An example of the fourth colorant is a toner similar to the first colorant described above.

The fourth colorant can be used alone or in combination of two or more types.

By appropriately selecting the fourth colorant, the fourth resin material can be adjusted to a desired color so that it is different in color from the first resin material, the second resin material, and the third resin material.

4-2. Preparation of mixed material Then, in addition to the first resin material, the powder material, the second resin material, and the third resin material, a fourth resin material having a small piece shape or a liquid shape is mixed to prepare a mixed material. The fourth resin material is preferably in a small piece shape.

When the fourth resin material has a small piece shape, for example, the first resin material, the powder material, the second resin material, and the third resin material are mixed as described above, and then the fourth resin material is further mixed.

The range of the mixing ratio of the fourth resin material having a small particle shape is, for example, the same as the above-mentioned range of the mixing ratio of the second resin material having a small particle shape. The range of the mixing ratio of the fourth resin material having a liquid shape is, for example, the same as the above-mentioned range of the mixing ratio of the second resin material having a liquid shape.

The mixed material is then cured and molded under the molding conditions described above (molding process).

As a result, the first resin material having a flake shape, the powder material, the second resin material having a flake shape or liquid shape, the third resin material having a flake shape or liquid shape, and the fourth resin material having a flake shape or liquid shape are mixed together to form an even more complex marble pattern. The first to fourth resin materials are then cured, forming a more complex marble pattern.

This process produces a molded product with a natural marble look and the desired shape.

This fourth embodiment can achieve the same effects as the first embodiment.

<Molding material>
Next, one embodiment of the molding material of the present invention will be described.

The molding material is used in the manufacturing method of the marble-like molded product described above, and includes the first resin material described above and the powder material described above.

The molding material may be a mixture of the first resin material and the powder material described above by the mixing method described above, or may be a kit that includes the first resin material and the powder material described above separately.

The molding material may further include at least one material selected from the group consisting of the second resin material, the third resin material, and the fourth resin material, as necessary.

In this case, the molding material may be a mixture of the first to fourth resin materials and the powder material described above by the mixing method described above, or a kit that includes each of the first to fourth resin materials and the powder material described above separately.

Such molding materials are ideal for use in the manufacturing method of the marble-like molded products described above, and can smoothly produce molded products with a natural marble-like texture close to that of natural marble.

<Modification>
In the first to fourth embodiments described above, the resin material having a small flake shape is prepared by cutting it out from a resin molding compound, but the preparation process of the resin material having a small flake shape is not limited to this. For example, the above-mentioned thermosetting resin composition and the above-mentioned reinforcing fiber may be supplied to a known kneader, and the resin material having a small flake shape may be directly discharged from the kneader.

In the first to fourth embodiments described above, only the mixed material is molded, but the molding process is not limited to this. For example, the mixed material may be placed on a separately prepared SMC, and the mixed material and the SMC may be press molded together.

These modifications can achieve the same effects as the first to fourth embodiments described above.

Specific numerical values of the compounding ratio (content ratio), physical property values, parameters, etc. used in the following description can be replaced with the upper limit (numerical value defined as "equal to or less than") or lower limit (numerical value defined as "equal to or more than" or "exceeding") of the corresponding compounding ratio (content ratio), physical property value, parameter, etc. described in the above "Description of the Invention." In addition, unless otherwise specified in the following description, "parts" and "%" are based on mass.

<<Example 1>>
<Preparation of first resin material>
A flask equipped with a thermometer, a nitrogen gas inlet tube, a reflux condenser, and a stirrer was used as a reactor. 2.0 mol of isophthalic acid, 5.5 mol of propylene glycol, and 5.0 mol of neopentyl glycol were charged into the reactor. Then, isophthalic acid, propylene glycol, and neopentyl glycol were subjected to a polycondensation reaction at a temperature of 200 to 210°C while stirring under a nitrogen gas atmosphere. When the acid value reached 10 mgKOH/g, the mixture was cooled to 150°C. Then, 8.0 mol of maleic anhydride was further charged into the reactor, and the reaction was continued again at 210 to 220°C until the acid value reached 27.0 mgKOH/g.

This resulted in the preparation of unsaturated polyester.

Next, 60 parts by mass of unsaturated polyester and 40 parts by mass of styrene were mixed to prepare a first unsaturated polyester resin.

Next, 80 parts by weight of the first unsaturated polyester resin, 15 parts by weight of crosslinked polystyrene (shrinkage reducing agent), 1.0 part by weight of t-butylperoxyisopropyl monocarbonate (curing agent), 0.05 part by weight of parabenzoquinone (polymerization inhibitor), 250 parts by weight of aluminum hydroxide (filler), 5 parts by weight of zinc stearate (release agent), and 4 parts by weight of green toner (polyester toner having first colorant, cobalt green) were mixed together. This prepared a thermosetting resin composition. The content of cobalt green in the green toner was approximately 20% by weight.

Next, 1.0 part by mass of magnesium oxide (thickener) was added to the thermosetting resin composition. After that, 40 parts by mass of chopped glass cut to 3 mm was added to the thermosetting resin composition. The thermosetting resin composition was then mixed using a known BMC kneader to prepare a 5 kg block of BMC (molding material).

Next, a number of small pieces of the first resin material were cut out from the BMC. The first resin material had a cube shape (dice shape), with each side measuring 10 mm.

<Preparation of powder pigment>
Titanium white (TiO ₂ ) was prepared as a white inorganic pigment. The titanium white was in a powder form. The maximum size of the white inorganic pigment (titanium white) was 0.3 μm.

<Preparation of Mixed Material>
Next, 0.1 parts by mass of a white inorganic pigment (titanium white) was applied to and mixed with 800 parts by mass of the first resin material having a flake shape. In this way, a mixed material was prepared. The white inorganic pigment (titanium white) was attached to the surface of the first resin material.

<Preparation of Molded Article>
The mixed material was then placed on a first flat mold (lower mold, 300 mm square). The second flat mold (upper mold, 300 mm square) was then moved toward the first flat mold, and the mixed material was sandwiched between the first and second flat molds, and the mixed material was hardened and molded at a molding temperature of upper mold/lower mold = 145 ° C./130 ° C., a molding pressure of 10 MPa, and a molding time of 6 minutes.

Through the above steps, a 300 mm square molded plate was prepared.

The molded plate had a natural marble-like pattern similar to that of natural marble. Figure 1 shows a plan view of the molded plate of Example 1.

<<Example 2>>
A flat molded product was prepared in the same manner as in Example 1. The amount of white inorganic pigment (titanium white) mixed was changed from 0.1 parts by mass to 4 parts by mass. The flat molded product had a natural marble-like pattern similar to that of natural marble. A photograph of the flat molded product of Example 2 in plan view is shown in FIG. 2.

<<Example 3>>
<Preparation of first resin material>
A first resin material having a flake shape was prepared in the same manner as in Example 1. Parabenzoquinone was replaced with hydroquinone. The green toner was replaced with a white toner (polyester toner containing titanium white). The titanium white content in the white toner was about 60% by mass.

<Preparation of powder pigment>
A red inorganic pigment, red iron oxide, was prepared. The red iron oxide was in a powder form. The maximum size of the red inorganic pigment (red iron oxide) was 0.5 μm.

<Preparation of Mixed Material>
Next, 0.5 parts by mass of red inorganic pigment (red iron oxide) was applied to and mixed with 800 parts by mass of the first resin material having a flake shape. In this way, a mixed material was prepared. The red inorganic pigment (red iron oxide) was attached to the surface of the first resin material.

<Preparation of Molded Article>
The mixed material was then cured and molded to prepare a plate molded product in the same manner as in Example 1. The plate molded product had a natural marble-like pattern similar to that of natural marble. A photograph of the plate molded product of Example 3 in plan view is shown in FIG. 3.

<<Example 4>>
<Preparation of first resin material>
In the same manner as in Example 3, a first resin material having a flake shape was prepared.

<Preparation of powder pigment>
A powdered pearlescent inorganic pigment (silver color) was prepared. The maximum size of the pearlescent inorganic pigment was 40 μm.

<Preparation of Mixed Material>
Next, 4 parts by mass of the pearl inorganic pigment was applied to and mixed with 800 parts by mass of the first resin material having a flake shape, thereby preparing a mixed material. The pearl inorganic pigment was attached to the surface of the first resin material.

<Preparation of Molded Article>
Next, the mixed material was cured and molded to prepare a plate molded product in the same manner as in Example 1. The plate molded product had a natural marble-like pattern similar to that of natural marble. A photograph of the plate molded product of Example 4 in plan view is shown in FIG.

<<Example 5>>
<Preparation of first resin material>
A first resin material having a flake shape was prepared in the same manner as in Example 1. The green toner was changed to the above-mentioned white toner (polyester toner having titanium white). The mixed amount of the white toner was set to 0.2 parts by mass.

<Preparation of second resin material>
A second resin material having a flake shape was prepared in the same manner as the first resin material in Example 5. In addition, the white toner was changed to a black toner (a polyester toner having a second colorant, carbon black). The carbon black content in the black toner was about 15% by mass.

<Preparation of powder pigment>
As in Example 1, titanium white was prepared as a white inorganic pigment.

The titanium white content in the white toner is about 60% by mass, and the purity of titanium white as a white inorganic pigment is 100% by mass. Therefore, the color tone of the white toner and the color tone of the white inorganic pigment are different from each other. Furthermore, the color tone of the first resin material and the color tone of the white inorganic pigment are different from each other.

<Preparation of Mixed Material>
Next, 0.3 parts by mass of a white inorganic pigment (titanium white) was applied to 400 parts by mass of the first resin material having a flake shape and mixed. Next, 400 parts by mass of the second resin material was mixed into the mixture of the first resin material and the white inorganic pigment (titanium white). In this way, a mixed material was prepared.

<Preparation of Molded Article>
The mixed material was then cured and molded to prepare a plate molded product in the same manner as in Example 1. The plate molded product had a natural marble-like pattern similar to that of natural marble. A photograph of the plate molded product of Example 5 in plan view is shown in FIG. 5.

<<Example 6>>
<Preparation of first resin material>
A first resin material having a flake shape was prepared in the same manner as in Example 1. In addition, the green toner was changed to a red toner (a polyester toner having red iron oxide as a first colorant). The mixed amount of the red toner was set to 0.05 parts by mass.

<Preparation of second resin material>
A second resin material having a flake shape was prepared in the same manner as the preparation of the first resin material in Example 6. The red toner was changed to the above-mentioned white toner (polyester toner containing titanium white as a second colorant). In addition, one side of the second resin material was set to 20 mm.

<Preparation of third resin material>
A second resin material having a flake shape was prepared in the same manner as the first resin material of Example 6 described above. The red toner was changed to a yellow toner (a polyester toner having a third colorant, yellow iron oxide). The content of yellow iron oxide in the yellow toner was about 10% by mass. In addition, one side of the third resin material was set to 20 mm.

<Preparation of powder pigment>
As in Example 1, titanium white was prepared as a white inorganic pigment.

<Preparation of Mixed Material>
Next, 0.5 parts by mass of a white inorganic pigment (titanium white) was applied to 400 parts by mass of the first resin material having a flake shape and mixed. Next, 200 parts by mass of the second resin material and 200 parts by mass of the third resin material were mixed into the mixture of the first resin material and the white inorganic pigment (titanium white). In this way, a mixed material was prepared.

<Preparation of Molded Article>
The mixed material was then cured and molded to prepare a plate molded product in the same manner as in Example 1. The plate molded product had a natural marble-like pattern similar to that of natural marble. A photograph of the plate molded product of Example 6 in plan view is shown in FIG.

<<Example 7>>
<Preparation of first resin material>
A flake-shaped first resin material was prepared in the same manner as in Example 1. The green toner was replaced with the above-mentioned white toner (polyester toner containing titanium white as a first colorant). The amount of white toner mixed was 0.1 parts by mass. In addition, 2 parts by mass of a white scale-shaped pattern material (size: about 2 mm, thickness: about 0.2 mm) was added.

<Preparation of second resin material>
A second unsaturated polyester resin was prepared by mixing 40 parts by mass of the unsaturated polyester prepared in the same manner as above with 120 parts by mass of styrene.

Next, 160 parts by mass of the second unsaturated polyester resin, 1.0 part by mass of t-butylperoxyisopropyl monocarbonate (curing agent), 0.008 part by mass of hydroquinone (polymerization inhibitor), 100 parts by mass of aluminum hydroxide (filler), 5 parts by mass of zinc stearate (release agent), and 5 parts by mass of beige toner (second colorant, polyester toner having titanium white, titanium yellow, red iron oxide, and carbon black) were mixed to prepare a second resin material having a liquid state. The titanium white content in the beige toner was approximately 51.0% by mass, the titanium yellow content was approximately 6.6% by mass, the red iron oxide content was approximately 0.5% by mass, and the carbon black content was approximately 0.2% by mass (same below).

<Preparation of powder pigment>
Carbon black was prepared as a black inorganic pigment.

<Preparation of Mixed Material>
Next, 0.001 parts by mass of a black inorganic pigment (carbon black) was applied to 700 parts by mass of the first resin material having a flake shape and mixed in. In addition, 0.5 parts by mass of a liquid second resin material was applied to 100 parts by mass of the first resin material having a flake shape.

Then, the first resin material coated with the black inorganic pigment was mixed with the first resin material coated with the second resin material. In this way, a mixed material was prepared.

<Preparation of Molded Article>
The mixed material was then cured and molded to prepare a plate molded product in the same manner as in Example 1. The plate molded product had a natural marble-like pattern similar to that of natural marble. A photograph of the plate molded product of Example 7 in plan view is shown in FIG.

<<Example 8>>
<Preparation of first resin material>
A first resin material having a small particle shape was prepared in the same manner as in Example 1. The green toner was changed to a gray toner (a polyester toner having a first colorant, titanium white, and carbon black). The mixed amount of the gray toner was set to 0.2 parts by mass. The content of titanium white in the gray toner was about 40% by mass, and the content of carbon black was about 5% by mass. The mixed amount of the gray toner was set to 0.2 parts by mass. In addition, one side of the first resin material was set to 20 mm.

<Preparation of second resin material>
A second resin material having a liquid state was prepared in the same manner as in Example 7. Note that the beige toner was changed to the above-mentioned white toner (polyester toner having the second colorant, titanium white).

<Preparation of third resin material>
A third resin material having a flake shape was prepared in the same manner as the preparation of the first resin material in Example 8 described above. The gray toner was replaced with the above-mentioned beige toner (a polyester toner having a third colorant, titanium white, titanium yellow, red iron oxide, and carbon black). The amount of beige toner mixed was set to 2 parts by mass. In addition, one side of the third resin material was set to 10 mm.

<Preparation of fourth resin material>
A fourth resin material having a flake shape was prepared in the same manner as the preparation of the first resin material in Example 8 described above. The gray toner was replaced with the above-mentioned white toner (polyester toner containing the fourth colorant, titanium white). The mixed amount of the white toner was set to 5 parts by mass. In addition, one side of the fourth resin material was set to 20 mm.

<Preparation of powder pigment>
As in Example 1, titanium white was prepared as a white pigment.

<Preparation of Mixed Material>
Next, 0.3 parts by mass of a white inorganic pigment (titanium white) was applied to 350 parts by mass of the first resin material having a flake shape and mixed with the material, and 2 parts by mass of the second resin material having a liquid shape was applied to 100 parts by mass of the third resin material having a flake shape.

Then, the mixture of the first resin material and the white inorganic pigment (titanium white), the mixture of the second resin material and the third resin material, and 350 parts by mass of the fourth resin material were mixed. In this way, the mixed material was prepared.

<Preparation of Molded Article>
Next, the mixed material was cured and molded to prepare a plate molded product in the same manner as in Example 1. The plate molded product had a natural marble-like pattern similar to that of natural marble. A photograph of the plate molded product of Example 8 in plan view is shown in FIG.

Claims (7)

preparing an uncured first resin material having a flake shape;
After the step of preparing the uncured first resin material, a step of mixing the uncured first resin material with a powder pigment having a maximum dimension of 1000 μm or less to prepare a mixed material;
After the step of preparing the mixed material, a step of curing the uncured first resin material to mold the mixed material is included;
The method for manufacturing a marble-like molded product , wherein in the step of preparing an uncured first resin material, a first resin material containing an uncured thermosetting resin is prepared . The method for manufacturing a marble-like molded product according to claim 1, characterized in that the powder pigment has a color and/or tone different from that of the uncured first resin material. The step of preparing the uncured first resin material includes:
preparing a first resin molding compound comprising the uncured first resin material;
3. The method for producing a marble-like molded product according to claim 1, further comprising the step of: cutting out the uncured first resin material having a small piece shape from the first resin molding compound. The method further includes a step of preparing an uncured second resin material having a color and/or a color tone different from that of the uncured first resin material and having a small particle or liquid form;
In the step of preparing the mixed material, the uncured first resin material, the powder pigment, and the uncured second resin material are mixed together ;
4. The method for manufacturing a marble-like molded product according to claim 1, wherein in the step of preparing the uncured second resin material, a second resin material containing an uncured thermosetting resin is prepared . The method further includes a step of preparing an uncured third resin material having a color and/or a color tone different from those of the uncured first resin material and the uncured second resin material, and having a small piece or liquid form;
In the step of preparing the mixed material, the uncured first resin material, the powder pigment, the uncured second resin material, and the uncured third resin material are mixed together;
5. The method for producing a marble-like molded product according to claim 4 , wherein in the step of preparing the uncured third resin material, a third resin material containing an uncured thermosetting resin is prepared . The method further includes a step of preparing an uncured fourth resin material having a color and/or a color tone different from those of the uncured first resin material, the uncured second resin material, and the uncured third resin material, and having a small piece or liquid form;
In the step of preparing the mixed material, the uncured first resin material, the powder pigment, the uncured second resin material, the uncured third resin material, and the uncured fourth resin material are mixed together ;
6. The method for producing a marble-like molded product according to claim 5, wherein in the step of preparing the uncured fourth resin material, a fourth resin material containing an uncured thermosetting resin is prepared . an uncured first resin material having a small particle shape;
A powder pigment having a maximum dimension of 1000 μm or less ;
The molding material , wherein the first resin material contains the uncured thermosetting resin .