JPS635261B2 - - Google Patents

Description

[Detailed description of the invention] The present invention relates to a patterned molded article and a method for molding the same.

Composite materials such as glass fiber reinforced synthetic resins have been used for building materials and the like. However, conventional materials have a monotonous appearance and color tone, making them unsuitable for applications that require a high-class appearance. Therefore,
A pattern layer is formed inside to form a patterned molded article with a high-class feel.

However, with conventional patterned molded products, patterned sheets are joined together to form a pattern layer, but it is necessary to sew the sheets together, and the color shading and misalignment of the pattern are noticeable at the joints, resulting in an appearance. was getting worse.

The object of the present invention is to solve the above-mentioned conventional drawbacks, and to provide a patterned molded product that can be easily molded, allows a beautiful pattern to appear, and does not make the seams of the patterned sheet body noticeable, and a method for molding the same. shall be. The patterned molded article of the present invention consists of a surface layer made of transparent or translucent synthetic resin, a pattern layer, and a back layer,
The pattern layer is characterized in that a plurality of sheet bodies each having a pattern are stacked on top of each other at their edges, and the edges of the pattern of the stacked sheets are formed in a zigzag shape. The method for molding a patterned molded article of the present invention involves forming a surface layer made of transparent or translucent synthetic resin in a mold, and forming a sheet with a pattern in which the edges of the pattern are formed in a zigzag shape. The sheet body is pasted, another sheet body with a pattern is overlaid on the edge of the pattern of the sheet body, and a back layer is laminated. An example of the patterned molded product of the present invention will be described below.

The surface layer 1 is preferably made of a transparent or translucent synthetic resin and has excellent heat resistance and boiling resistance. That is, thermosetting resins such as unsaturated polyester resins and epoxy resins, or thermoplastic resins such as acrylic resins are suitable, and a liquid uncured thermosetting resin is sprayed or applied onto a mold and cured. Alternatively, an acrylic resin plate is molded by vacuum forming or the like.

The surface layer 1 may be formed by stacking transparent or translucent synthetic resin layers reinforced with glass fibers or the like, or may be composed of a single transparent or translucent synthetic resin layer reinforced with glass fibers or the like. . A pattern layer 2 is formed by laminating the surface layer 1. The pattern layer 2 is for making a pattern appear on the patterned molded body,
The main body is a sheet body 3 on which a pattern is applied by printing, painting, dyeing, bleaching, etc. In FIGS. 1 and 2, a strip-shaped sheet member 3a is first attached to the surface layer 1. As shown in FIGS. A pattern 4 is formed in the center of the belt-shaped sheet body 3a, and an edge portion 5 of the pattern 4 is formed in a zigzag shape. The edge portion 6 of the band-shaped sheet body 3a other than the pattern 4 is transparent or semi-transparent. The formation of transparent or translucent edge portions 6 other than the pattern 4 of the belt-shaped sheet body 3a means at least the state in which the patterned molded body is formed, and the belt-shaped sheet body 3a When 3a is taken out alone, it may appear opaque. On the belt-shaped sheet body 3a, a sheet body 3b having another pattern formed in a wide width is placed, and the pattern of the sheet body 3b is overlapped on the edge 5 of the pattern 4 of the belt-shaped sheet body 3a. , the pattern is continuous across the entire surface. Due to the zigzag edge portion 5 of the pattern 4 of the belt-shaped sheet body 3a, even in the case of a stone grain pattern, a wood grain pattern, other continuous patterns, or spotted patterns, the seams become discontinuous and become inconspicuous.

The patterned sheet body 3 is made of acrylic resin film, polyethylene resin film, polyester resin nonwoven fabric, glass mat, glass cloth, or the like. If the sheet body 3 is made of a wide synthetic resin film, it is preferable to provide through holes for defoaming.

Paste the patterned sheet body 3 on the surface layer 1,
To form the pattern layer 2, a transparent or translucent liquid uncured thermosetting resin is sprayed or applied onto the surface layer 1, and the pattern is applied to the sheet body 3 while defoaming with a roller or rubber spatula. The pattern layer 2 is formed by pasting the thermosetting resin and curing the thermosetting resin. Furthermore, if the patterned sheet body 3 is made of synthetic resin film or nonwoven fabric, the pattern will not remain in the pattern layer even if it is partially or completely dissolved or swollen in the synthetic resin or solvent contained in the pasting resin. Any material that remains in the container without losing its shape is fine. In the band-shaped sheet body 3a on which the zigzag-shaped edge portion 5 of the pattern 4 is formed, a transparent or translucent portion is formed on the edge portion 6 of the sheet 3a other than the pattern 4, and the band-like shape is formed by the zigzag notch effect. Even if the edge of the strip-shaped sheet 3a shrinks or the strip-shaped sheet 3a is made of nonwoven fabric or glass cloth and the edge of the sheet loosens, the pattern 4 will not be cut. This has the advantage of not causing any disturbance.

A back layer 7 is laminated on the pattern layer 2. Back layer 7
is fiber-reinforced synthetic resin, plywood, metal plate, concrete, fiber-reinforced concrete, resin concrete,
Various materials such as gypsum board are used. The back layer 7 provides rigidity, strength, and thickness to the patterned molded body. Figure 3,
FIG. 4 shows another example of a patterned molded body, and FIG. 3 shows a sheet body 3c with a pattern to be used. The patterned sheet body 3c is the sheet body 3a,
It is made of the same material as 3b and is relatively wide. Most of the patterned sheet body 3c has a pattern 4 partially having a color pattern with relatively low hiding power.
A is formed, and a pattern 4b having a large hiding power is formed entirely near the edge of the sheet 3c. The edge portion 5 of the pattern 4b is formed in a zigzag shape. A transparent or translucent portion is formed in the pattern 4b and the edge portion 6 of the sheet 3c. The pattern 4b having a large hiding power and the transparent or translucent edge 6 may be provided on all the edges of the patterned sheet body 3c, or may be provided only on one edge.

In order to mold the patterned molded body shown in FIG. 4 using the patterned sheet body 3c, first, the surface layer 1 made of transparent or translucent synthetic resin is formed on the mold in the same manner as described above. do. A sheet body 3c on which a pattern is applied by spraying or applying a synthetic resin for pasting is attached to the surface layer 1, and the pattern 4b of the sheet body 3c having a large hiding power is applied to the edge of another sheet body 3c. The other sheet body 3c is attached so that the patterns 4a or 4b overlap. In FIG. 4, the back layer 7 is composed of three layers. 8 is a transparent or translucent synthetic resin layer, which may be reinforced with fibers. 9 is an opaque layer, which is hidden with a colored synthetic resin or the like. Reference numeral 10 denotes a back layer, which is made of fiber-reinforced synthetic resin, plywood, metal plate, concrete, fiber-reinforced concrete, resin concrete, gypsum board, etc., and supports the entire structure.

After being laminated and molded as described above, the molded product is removed from the mold to obtain a patterned molded product. In the patterned molded product shown in FIG.
I can see a. In the colored portion of the pattern 4a with low hiding power, the opaque layer 9 is visible through the transparent or semi-transparent synthetic resin layer 8, and the surface layer 1, pattern layer 2, transparent or semi-transparent synthetic resin layer 8, and opaque layer 9 are visible. It becomes a composite color. In the pattern 4a, there is a phase difference between the color pattern portion with low hiding power that can be seen through to the opaque layer 9 and the other portions, giving the appearance of a deep three-dimensional pattern.

At the joint portion of the patterned sheet body 3c, the pattern 4b having a large hiding power can be seen at the edge portion of the sheet body 3c which is overlapped on top of the surface layer 1.
The pattern 4a or 4b of the sheet body 3c superimposed thereon, the transparent or translucent synthetic resin layer 8, and the opaque layer 9 are hardly seen through. Then, the color tone of the pattern 4b having a large hiding power is the same as that of the pattern 4a.
Surface layer 1 in the colored pattern part with low hiding power,
The color of the pattern layer 2 is similar to that of the transparent or translucent synthetic resin layer 8 and the opaque layer 9, and the sheet body 3c
This is done so that no color shading occurs near the joints.

Example A transparent resin made of vinyl ester resin, hardening agent, and low shrinkage agent is sprayed onto a preheated synthetic resin mold coated with a mold release agent, and cured to increase the thickness.
A surface layer 1 of 0.3 mm was formed. Next, a transparent adhesive resin consisting of a vinyl ester resin, a hardening agent, and a low shrinkage agent is applied to a thickness of 0.4 mm using a roller, and the edges of the patterned acrylic resin sheet body 3c with a thickness of 20 μm are spliced together. The pattern layer 2 was formed by pasting the resin while defoaming and curing the resin.

The acrylic resin sheet body 3c is coated with a vinyl chloride-acrylic resin ink, and has a spot-like pattern 4a having a colored portion with relatively low hiding power, and a band-like pattern with the same pattern as the pattern 4a on the edge of the sheet body 3c. A cream-colored pattern with great hiding power 4
b is formed. The edge 5 of the pattern 4b was formed in a zigzag shape, and a transparent portion was formed at the edge 6 of the sheet body 3c.

Next, chopped strand glass mats with an areal density of 450 g/m ² are stacked one on top of the other, and a transparent resin consisting of vinyl ester resin, hardening agent, and low shrinkage agent is sprayed onto the mat, defoamed and cured, and the thickness is 1 mm. A transparent or translucent synthetic resin layer 8 was formed. Then, a white opaque resin consisting of vinyl ester resin, hardening agent, low shrinkage agent and titanium white pigment is sprayed and cured.
An opaque layer 9 of 0.3 mm was formed, and a back layer 10 was formed by laminating a 9 mm thick plywood board with unsaturated polyester resin and chopped strand glass mat.

After the molding is completed, the patterned molded body is taken out from the mold, and the joint portion of the patterned sheet bodies 3c, 3c is the zigzag-shaped edge of the pattern 4b at the edge of the sheet body 3c near the surface layer 1. Part 5 becomes camouflage,
A molded product with an inconspicuous and beautiful pattern with intermittent seams was obtained. Furthermore, by providing the patterned sheet body 3c with a pattern 4a partially having a color pattern with low hiding power, the pattern has a deep three-dimensional effect, and at the joint portion of the sheet bodies 3c, 3c, Concealed by the pattern 4b with great concealing power,
It is approximated to the composite color up to opaque layer 9 of pattern 4a,
I could not feel the shade of color near the seams.

Since the patterned molded article of the present invention and its molding method have the above-described configuration, the edge portions of the sheet bodies are overlapped with each other without sewing the sheet bodies to which the pattern is to be applied. Even when molded, the zigzag edge of the pattern on the sheet body with a pattern close to the surface layer becomes camouflage, and a beautiful patterned molded product with inconspicuous seams can be obtained.

In addition, in the patterned molded product of the present invention, a transparent or translucent portion is formed between the edge of the patterned sheet body and the zigzag edge of the pattern, so that the patterned sheet body This also prevents the pattern from being cut from its edges, and also prevents the pattern from becoming disordered due to unraveling of the edges when the patterned sheet is made of non-woven fabric or glass cloth.

[Brief explanation of the drawing]

Figures 1 and 3 are plan views showing an example of a patterned molded article of the present invention and a patterned sheet body used in its molding method, and Figures 2 and 4 are examples of the patterned molded article of the present invention. FIG. 1 is the surface layer, 2 is the pattern layer, 3, 3a, 3b, 3
c is a sheet body with a pattern, 4 is a pattern, 4a is a pattern partially having a color pattern with low hiding power, 4b
5 is a pattern with a large hiding power, 5 is a zigzag edge, 6 is an edge of a transparent or translucent sheet body without a pattern, 7 is a back layer,
8 is a transparent or translucent synthetic resin layer, 9 is an opaque layer, and 10 is a back layer.

Claims (1)

[Claims] 1. Consisting of a surface layer made of transparent or translucent synthetic resin, a pattern layer, and a back layer, the pattern layer is formed by forming a plurality of sheets with patterns mutually at their edges. A patterned molded body characterized in that the sheets are stacked one on top of the other, and the edges of the pattern on the sheets stacked on top are formed in a zigzag shape. 2. A surface layer made of transparent or translucent synthetic resin is formed on a mold, and a sheet body with a zigzag pattern is attached to the mold, and the edge of the pattern on the sheet body is pasted. 1. A method for forming a patterned molded article, which comprises overlapping and pasting the edge portion of another sheet body on which a pattern has been applied, and laminating a back layer. 3. A sheet body with a pattern formed in a zigzag shape at the edge of the sheet body has a transparent or translucent portion without a pattern formed on the edge of the sheet body, as claimed in claim 2. A method for forming a patterned molded article as described in Section 1.