TWI739282B - Method for manufacturing resin molded product and resin molded product - Google Patents

Abstract

The subject of the present invention is to provide a method of manufacturing a resin molded product and a resin molded product that easily display a desired pattern. The method of manufacturing the resin molded product 1 is a method of manufacturing the resin molded product 1 by using a mold 2 having a plurality of depressions 3 on the molding surface 20. The manufacturing method includes a pattern injection step, a pattern hardening step, and a base forming step. In the pattern injection step, the resin composition 4 for pattern formation is injected into the plurality of depressions 3. The pattern hardening step hardens the pattern-forming resin composition 4 injected into the plurality of depressions 3. In the base forming step, a base resin composition 5 having a different composition from the pattern forming resin composition 4 is injected into the mold 2 so as to cover the molding surface 20 and cured.

Description

Manufacturing method of resin molded product and resin molded product

The present invention relates to a method of manufacturing a resin molded product and a resin molded product.

In the past, we have generally known the manufacturing method of artificial marble (for example, refer to Patent Document 1 (Japanese Laid-open Patent Publication No. 2002-36259)).

The manufacturing method described in Patent Document 1 sprays paint on the inner surface of a casting mold to form a marble-patterned resin layer in a semi-cured state, and then injects a casting resin composition into the casting mold and molds and hardens it. To make artificial marble.

However, in the above-mentioned artificial marble manufacturing method, when the marble pattern resin layer is not sufficiently hardened, there are doubts as follows: the pattern of the marble pattern resin layer is disordered due to the injection of the resin composition for casting, and the desired pattern cannot be obtained. Shown on the surface of artificial marble.

[Prior Technical Literature] [Patent Literature]

Patent Document 1: Japanese Patent Publication No. 2002-36259

The object of the present invention is to provide a method for manufacturing a resin molded product and a resin molded product that easily display a desired pattern.

The method of manufacturing a resin molded product of one aspect of the present invention is a method of manufacturing a resin molded product by using a mold having a plurality of depressions on the molding surface. The manufacturing method includes a pattern injection step, a pattern hardening step, and a base forming step. In the pattern injection step, the resin composition for pattern formation is injected into the plurality of depressions. The pattern hardening step hardens the resin composition for pattern formation that has been injected into the plurality of depressions. In the step of forming the base, a resin composition for a base having a composition different from the resin composition for forming a pattern is injected into the mold so as to cover the molding surface, and the resin composition is cured.

In addition, a resin molded article of one aspect of the present invention includes a base portion and a plurality of protrusions protruding from the surface of the base portion. The plurality of protrusions are formed using a resin composition for forming a pattern, and the base part is formed using a resin composition for a base having a different composition from the resin composition for forming a pattern.

1: Resin molded product

2: Mould

2a: Lower mold (mold)

2b: Upper die (mold)

3: sunken

3a: first depression

3b: second depression

4: Resin composition for pattern formation

4a: The first resin composition

4b: Second resin composition

5: Resin composition for substrate

6: recess

10: base part

11: protrusion

11a: first protrusion

11b: second protrusion

11c: third protrusion

11d: Fourth resin composition

12: Kitchen console

12a: Flat part

12b: rear gear

12c: Curtain board

12d, 12e: through hole

20: forming surface

21: recess

22: recess

23: Mould slot

30: Non-pattern injection area

100: surface

101: part

210: Bottom

211: Part

220: Bottom

1A to C are cross-sectional views sequentially showing the process of manufacturing the resin molded article according to the first embodiment of the present invention.

Fig. 2A is a plan view schematically showing the above-mentioned resin molded product, Fig. 2B is a cross-sectional view taken along line A-A of Fig. 2A, and Fig. 2C is a cross-sectional view showing an enlarged part B of Fig. 2B.

Fig. 3 is a perspective view showing an example of a kitchen worktop constructed with the above-mentioned resin molded product.

Fig. 4 is a cross-sectional view schematically showing the mold used to manufacture the above-mentioned resin molded product.

Fig. 5 is a plan view showing another example of the above-mentioned resin molded product.

6A to 6D are cross-sectional views sequentially showing the process of manufacturing the resin molded article according to the second embodiment of the present invention.

7A to D are cross-sectional views sequentially showing the process of manufacturing the resin molded product of the third embodiment of the present invention.

8A is a plan view showing the forming surface of the mold in the pattern injection step shown in FIG. 7A, and FIG. 8B is a plan view showing the forming surface of the mold in the pattern hardening step shown in FIG. 7B.

9A is a cross-sectional view schematically showing the mold used in the method of manufacturing a resin molded article of the sixth embodiment of the present invention, FIG. 9B is an enlarged cross-sectional view showing part D of FIG. 9A, and FIG. 9C is a cross-sectional view showing E in FIG. 9A Partially enlarged cross-sectional view.

10A is a cross-sectional view schematically showing the mold used in a modification of the above-mentioned resin molded product manufacturing method, FIG. 10B is an enlarged cross-sectional view showing part F of FIG. 10A, and FIG. 10C is an enlarged part G of FIG. 10A The cross-sectional view shown.

[Preferable form of implementing the invention]

1. Implementation form 1

1-1. Summary

As shown in Figures 1A to C, the method of manufacturing resin molded article 1 of Embodiment 1 (hereinafter only referred to as "manufacturing method") is to use a mold 2 having a plurality of depressions 3 on the molding surface 20 to manufacture resin Method of molding product 1.

The manufacturing method includes a pattern injection step, a pattern hardening step, and a base forming step. In the pattern injection step, the resin composition 4 for pattern formation is injected into the plurality of depressions 3. The pattern hardening step hardens the pattern-forming resin composition 4 injected into the plurality of depressions 3. In the base molding step, a base resin composition 5 having a different composition from the pattern forming resin composition 4 is injected into the mold 2 so as to cover the molding surface 20 and cured. In this embodiment, the plurality of depressions 3 are grooves extending in one direction. That is, the plural recesses 3 can be said to be plural grooves in other words.

In the above-mentioned manufacturing method, the resin composition for pattern formation 5 is injected in the state where the resin composition 4 for pattern formation is arranged in each recess 3, so that the resin composition for pattern formation caused by the injection of the resin composition 5 for the base can be suppressed The position of 4 is misplaced, and the pattern is disordered. Therefore, the above-mentioned manufacturing method can easily display a desired pattern on the surface of the resin molded product 1.

In addition, in the resin molded product 1 manufactured by this manufacturing method, a plurality of protrusions 11 formed by the resin composition 4 for pattern formation protrude from the surface 100 of the base 10 formed by the resin composition 5 for the base. . Therefore, in this resin molded product 1, the pattern formed by the plurality of protrusions 11 is displayed three-dimensionally, so that the desired pattern can be effectively displayed.

1-2. Details

Hereinafter, the manufacturing method and the resin molded product 1 of this embodiment will be described in more detail.

2A to 2C schematically show an example of the resin molded product 1 manufactured by the manufacturing method of this embodiment. On the surface of the resin molded product 1, a plurality of protrusions 11 are used to three-dimensionally display a layered pattern of sedimentary rock style, that is, a straight pattern. The resin molded product 1 constitutes, for example, a kitchen counter 12 as shown in FIG. 3.

The kitchen worktop 12 is set on the top plate of the kitchen appliance in the kitchen. The kitchen console 12 includes a rectangular flat plate portion 12a in a plan view, a rear stop 12b erected from one end of the flat plate 12a in the short-side direction, and a curtain panel 12c hanging down from the other end of the flat plate 12a in the short-side direction. The flat plate portion 12a is provided with two through holes 12d and 12e penetrating in the thickness direction thereof. The through hole 12d is a part where a heating conditioner such as a gas conditioner or an electromagnetic conditioner is installed, and the through hole 12e is a part where a water tank is installed.

On the upper surface of the flat plate portion 12a, the surface of the rear fence 12b facing the curtain panel 12c, and the surface of the curtain panel 12c facing the opposite side of the rear fence 12b, a plurality of protrusions 11 each show a layered pattern of sedimentary rock style. In the kitchen counter 12, the plurality of protrusions 11 each extend along the longitudinal direction of the kitchen counter 12.

Fig. 4 schematically shows an example of the mold 2 used in the manufacturing method of this embodiment. The mold 2 has a lower mold 2a and an upper mold 2b. Fig. 4 schematically shows the recess 3 and the mold 2, and is different from the actual dimensional relationship between the recess 3 and the mold 2.

The lower mold 2a has a recess 21 on its upper surface. The upper mold 2b has a recess 22 on its lower surface. The upper mold 2b can be raised and lowered in the up and down direction. In the mold 2, in a state where the upper surface of the lower mold 2a overlaps the lower surface of the upper mold 2b, a cavity 23 is formed by the recessed portion 21 and the recessed portion 22 (see FIG. 1B).

The bottom surface 210 of the recess 21 is a molding surface 20 that molds the surface of the resin molded product 1. The bottom surface 210 is provided with a plurality of depressions 3.

The plurality of depressions 3 are grooves extending in one direction, respectively. The plurality of recesses 3 are arranged in such a way that they are spaced apart in the width direction. Hereinafter, the direction in which the plurality of depressions 3 extend is set to the direction D1, and the direction in which the plurality of depressions 3 are arranged is set to the direction D2 to describe each configuration. The direction D1 and the direction D2 are directions orthogonal to each other.

The cross section orthogonal to the longitudinal direction of each of the plurality of depressions 3 is triangular. Here, the triangle does not mean the shape of a triangle in a strict sense, but also includes a shape with a chamfered corner (for example, the corner at the bottom of the recess 3), that is, an approximately triangular shape. The depth L1 (length in the vertical direction) of each of the plurality of depressions 3 is 50 μm or more and 400 μm or less. In addition, the respective depths L1 of the plurality of recesses 3 may be the same as each other or different from each other.

The length (meaning the length in the direction D1), width (meaning the length in the direction D2), arrangement, and shape of the plurality of recesses 3 are appropriately set in accordance with the pattern to be displayed on the surface of the resin molded product 1. The plural recesses 3 are provided, for example, to have the same length, width, arrangement, and shape as the plural protrusions 11 shown in FIG. 2A or FIG. 5.

The length of the plurality of recesses 3 can be appropriately selected, and the length of the direction D1 of the bottom surface 210 of the recess 21 can be the same or different. In addition, the widths of the plurality of recesses 3 may be the same as each other or different from each other. In addition, the plurality of depressions 3 may be a straight line, a straight line in which a part of the longitudinal direction is cut, or a meandering shape, and the width of a part of the longitudinal direction and other parts may be different from each other. In addition, among the plurality of recesses 3, the interval between two adjacent recesses 3 can be appropriately set.

As shown in FIG. 1A, the plurality of recesses 3 includes a first recess 3a and a second recess 3b. The first recess 3a and the second recess 3b are each injected with a resin composition 4 for pattern formation having different compositions.

In the bottom surface 210 of the recess 21 of the lower mold 2a, the part 211 other than the plural recesses 3 (the part between the two adjacent recesses 3 and the part located outside the recess 3 at both ends) are provided with more than recesses 3Rough surface with shallower, minute and plural recesses (not shown). In addition, the surface of each recess 3 is also provided with a plurality of minute recesses. The depth of the recess is 200 μm or less, for example. The shape of the cross section orthogonal to the direction D2 of the part 211 and the shape of the cross section orthogonal to the direction D1 of the part 211 are, for example, triangular waves. The part 211 is polished with a grinding wheel, and the upper end surface is set to be a flat surface. In addition, the portion 211 is polished with a grinding wheel, and the minute convex surface of the portion 211 is polished, whereby the surface of the portion corresponding to the portion 211 in the resin molded product 1 is less likely to have minute recesses, and the cleaning performance is improved. The polishing of the part 211 is performed, for example, to a level such that the surface formed by the top of the protrusion of the part 211 is glossy. The polishing method of part 211 can also be used Use polishing pads other than grinding wheels for physical polishing or chemical polishing. For the polishing of the part 211, as long as there is a difference in hue between the surface formed by the top of the protrusion and the surface formed by the bottom of the protrusion, the degree of polishing can be appropriately selected.

As shown in FIG. 4, the bottom surface 220 of the recessed part 22 of the upper mold|type 2b is a flat surface. In addition, the flat surface is not limited to a flat surface in a strict sense, but also includes an approximately flat surface with minute concavities and convexities. The bottom surface 220 constitutes a molding surface on which the back surface of the resin molded product 1 is molded.

Next, the resin molded product 1 manufactured using the above-mentioned mold 2 will be described in detail.

As shown in FIGS. 2A to 2C, the resin molded product 1 has a plate-shaped base portion 10 and a plurality of protrusions 11 protruding from the surface 100 of the base portion 10. The plural protrusions 11 are formed by the resin composition 4 for pattern formation, and the base part 10 is formed by the resin composition 5 for the base. In addition, FIGS. 2A to 2C schematically show the base portion 10 and the plurality of protrusions 11, which are different from the actual base portion 10 and protrusions 11 in size relationship.

The length (meaning the length in the direction D1), width (meaning the length in the direction D2), arrangement, and shape of the plurality of protrusions 11 correspond to the length, width, arrangement, and shape of the plurality of recesses 3 of the mold 2.

In the resin molded product 1 shown in FIG. 2A, the plurality of protrusions 11 respectively extend in a straight line along the direction D1. The respective widths of the plural protrusions 11 are the same as each other. The cross section of each of the plurality of protrusions 11 is triangular. The plurality of protrusions 11 are arranged with spaces in the direction D2. The plurality of protrusions 11 are not equally spaced, but are arranged at random intervals.

The portions 101 between the adjacent protrusions 11 in the surface 100 of the base portion 10 are each formed with minute concave and convex surfaces, and the concave bottom surface of the concave and convex surface becomes a glossy flat surface.

The resin composition 4 for pattern formation and the resin composition 5 for a base are each equipped with the thermosetting resin used as a main material, the filler added to the thermosetting resin, and a coloring agent. In this embodiment, among the resin composition 4 for pattern formation and the resin composition 5 for a base, the composition system of a thermosetting resin and a filler is common, and the composition system of a coloring agent is mutually different.

The thermosetting resin is not particularly limited, and can be suitably selected from various known monomers, mixtures of such monomers and polymers, and the like. Thermosetting resins include, for example, polyester resins such as unsaturated polyesters, acrylic resins such as melamine (meth)acrylate, glycidyl (meth)acrylate, and methyl (meth)acrylate, vinyl resins, etc. Ester resin, epoxy resin, etc. In addition, the expression of (meth)acrylic acid means acrylic acid or methacrylic acid. Specific examples of (meth)acrylic monomers include methyl (meth)acrylate, ethyl (meth)acrylate, butyl (meth)acrylate, and 2-ethyl (meth)acrylate Hexyl ester, benzyl (meth)acrylate, etc.

Furthermore, thermosetting resins include radical hardening resins such as unsaturated polyester resins and acrylic resins, epoxy resins, urethane resins, and the like.

The unsaturated polyester resin is a thermosetting resin obtained by dehydration condensation of a polybasic acid component with an unsaturated polybasic acid as an essential component, a glycol component and/or an epoxy compound component. Polyacid component system A compound having a substituent that can react with the hydroxyl group of the glycol component or the epoxy group of the epoxy component to produce an ester bond. The polybasic acid component is an unsaturated polybasic acid having two or more substituents as an essential component, and a saturated polybasic acid or a monovalent acid may also be used as a part thereof. For unsaturated polybasic acids, maleic acid, fumaric acid, aconitic acid, itaconic acid, or acid anhydrides of these acids, and derivatives of these acids (halides, etc.) are listed, and these two types may also be used. Combine the above. As far as glycol components are concerned, ethylene glycol, propylene glycol, dipropylene glycol, butylene glycol, triethylene glycol, neopentyl glycol, trimethylene glycol, glycerin, hydrogenated bisphenol A, bisphenol A, and bisphenol are listed S, etc., can also be used in combination of two or more of these types. The epoxy component includes ethylene oxide, propylene oxide, etc., and two or more of these types may be used in combination.

Acrylic resin, can be methacrylic acid/acrylic acid or these esters as the main component of unsaturated monomer polymer, or polymerized unsaturated monomer obtained by dissolving unsaturated monomer polymer By. The main components of unsaturated monomers include methacrylic acid, methyl methacrylate, ethyl methacrylate, butyl methacrylate, 2-hydroxyethyl methacrylate, and glycidyl methacrylate. Ester, acrylic acid, methyl acrylate, ethyl acrylate, butyl acrylate, 2-ethylhexyl acrylate, TMPTA (trimethylolpropane triacrylate), etc.

As far as the filler is concerned, it can be suitably selected from known inorganic fillers. In terms of fillers, for example, aluminum hydroxide, calcium hydroxide, magnesium hydroxide, talc, quartz powder, silica, diatomaceous earth, gypsum, glass powder, marble, limestone, aluminum silicate, calcium silicate , Or borax. In addition, the fillers include calcium sulfite, calcium sulfate, barium sulfate, silicon dioxide, calcite, titanium oxide, antimony trioxide, calcium carbonate, nickel powder, iron powder, zinc powder, copper powder, and iron oxide. , Glass beads, glass fiber, or silicone. Furthermore, As for the filler, alumina (alumina) or graphite is also cited. For these inorganic fillers, not only one kind but also two or more kinds may be added to the thermosetting resin.

As for the coloring agent, white particles, gray particles, black particles, pearl particles, and other colored granular pattern materials, pigments or dyes, or a combination thereof are exemplified. The colorant is a material used to change the appearance of the resin composition.

The resin composition 4 for pattern formation and the resin composition 5 for the base can each be added with the above-mentioned fillers and coloring agents to the thermosetting resin, and various components such as curing agents and antibacterial agents can also be added in accordance with the required physical properties. .

In the manufacturing method shown in FIG. 1A, the resin composition 4 for pattern formation contains the 1st resin composition 4a, and the 2nd resin composition 4b whose composition system differs from the 1st resin composition 4a. The first resin composition 4a and the second resin composition 4b have different colorant compositions and have different appearances. The first resin composition 4a has, for example, white particles as a colorant, and the second resin composition 4b contains gray particles as a colorant. In addition, the type of coloring agent contained in the resin compositions 4a and 4b can be appropriately selected.

In the resin molded product 1 shown in FIG. 2A, the plural protrusions 11 include a first protrusion 11a and a second protrusion 11b. The first protrusion 11a is the protrusion 11 formed by the first recess 3a, and the second protrusion 11b is the protrusion 11 formed by the second recess 3b. The first protrusion 11a is formed using the first resin composition 4a, and the second protrusion 11b is formed using the second resin composition 4b. The number of the first protrusions 11a contained in the plural protrusions 11 and the first The number of the two protrusions 11b can be appropriately set. In addition, the plural protrusions 11 may further include protrusions formed by a resin composition having a composition system different from that of the resin compositions 4a and 4b.

The base part 10 contains, for example, a beige-colored white or gray pigment as a colorant. In this embodiment, the resin composition 4 for pattern formation has higher heat resistance than the resin composition 5 for a base. The resin composition 4 for pattern formation uses fillers containing aluminum hydroxide or silicon dioxide to improve heat resistance. In addition, the resin composition 4 for pattern formation may have the same heat resistance as that of the resin composition 5 for a base.

In the resin molded product 1 described above, there are a plurality of protrusions 11 protruding from the surface 100 of the base portion 10, and a laminated pattern (in other words, a straight pattern) formed by the plurality of protrusions 11 is displayed three-dimensionally. The surface of the molded product 1 effectively displays a pattern.

In addition, since the plural protrusions 11 include the first protrusion 11a and the second protrusion 11b having different appearances from each other, various patterns can be displayed on the surface of the resin molded product 1.

Next, another example of the resin molded product 1 shown in FIG. 5 will be described.

The plurality of protrusions 11 includes: a first protrusion 11a formed with a first resin composition 4a, a second protrusion 11b formed with a second resin composition 4b, and a third protrusion formed with a third resin composition 4c 11c, and the fourth protrusion 11d formed by the fourth resin composition 4d.

The first resin composition 4a has white particles as a colorant, the second resin composition 4b has gray particles as a colorant, and the third resin composition 4c has pearl particles as a colorant. The fourth resin composition 4d is set to be more transparent than the other resin compositions 4a, 4b, 4c and the resin composition 5 for a base. In the fourth resin composition 4d, the amount of the pigment or dye added to the thermosetting resin as the main material is reduced to be lower than that of the other resin compositions 4a, 4b, 4c and the resin composition 5 for a base, thereby making it transparent.

In this resin molded product 1, the first to fourth protrusions 11a, 11b, 11c, and 11d are randomly arranged at intervals in the direction D2. The width of the first to fourth protrusions 11a, 11b, 11c, 11d is suitably selected from 4mm, 8mm, 10mm, 12mm, 15mm, and 20mm, for example. The first to fourth protrusions 11a, 11b, 11c, and 11d include a straight line and a meandering one.

In the other example of the resin molded product 1 described above, a three-dimensional display of a laminated pattern formed by a plurality of types of randomly arranged layers with different appearances can effectively display a pattern on the surface of the resin molded product 1. In addition, in other examples of this resin molded product 1, the appearance of the surface is similar to that of sedimentary rock.

1-3. Manufacturing method of resin molded products

Next, a method of manufacturing the resin molded product 1 using the mold 2 described above will be described.

The manufacturing method of this embodiment includes a pattern injection step, a pattern hardening step, and a base forming step. The pattern injection step, pattern hardening step, and base forming step are performed in this order.

In the pattern injection step, as shown in FIG. 1A, the pattern forming resin composition 4 is injected into the plurality of recesses 3 of the bottom surface 210 (that is, the molding surface 20) of the recess 21 of the lower mold 2a. In the plural recesses 3, the resin composition 4 for pattern formation is injected into each of them, and the entire recesses 3 are filled. The first resin composition 4a is injected into the first depression 3a in the plurality of depressions 3, and the second resin composition 4b is injected into the second depression 3b.

The resin composition 4 for injection pattern formation uses, for example, an automatic coater. The automatic coating machine can, for example, perform: movement toward the direction D1 and the direction D2; the selection of the type of the resin composition 4 for pattern formation to be injected; and the control of the injection pressure. The automatic coating machine injects the pattern forming resin composition 4 into the bottom surface 210 (that is, the molding surface 20) of the lower mold 2a in accordance with the recorded arrangement pattern of the plurality of depressions 3. The resin composition 4 for pattern formation is injected into the plural recesses 3, and the entire recesses 3 are filled.

The pattern hardening step hardens the pattern-forming resin composition 4 injected into the plurality of depressions 3. The hardening of the resin composition 4 for pattern formation is performed by heating the lower mold 2a by a heating device provided in or around the lower mold 2a. The heating device is, for example, a pipe that circulates heating fluid such as warm water or hot water, or an electric heater.

In the substrate forming step, as shown in FIG. 1B, the upper surface of the lower mold 2a overlaps the lower surface of the upper mold 2b, and the recesses 21 and 22 are used to form a mold groove 23, and the resin composition 5 for the substrate is injected into this mold. Slot 23. The resin composition 5 for a base is injected into the mold 2 so as to cover the molding surface 20 of the lower mold 2a. At this time, the resin composition 5 for a base is injected into the mold 2 along the longitudinal direction (that is, the direction D1) of the plurality of depressions 3, for example. In addition, the resin composition 5 for a base can also be injected into the mold 2 along the width direction of the plurality of depressions 3 (that is, the direction D2).

Next, the resin composition 5 for a base injected into the mold 2 is cured. The hardening of the resin composition 5 for the base is performed by heating the molds 2a and 2b by a heating device provided in or around the molds 2a and 2b.

Next, as shown in FIG. 1C, the resin molded product 1 is taken out from the mold 2.

1-4. Effect

The manufacturing method of the present embodiment described above is to inject the resin composition 5 for a base in a state where the resin composition 4 for forming a pattern is arranged in each recess 3. Therefore, it is possible to suppress the infusion of the resin composition 5 for the base. The position of the resin composition 4 for pattern formation is shifted, and the pattern becomes disordered. With this, the manufacturing method of the present embodiment can easily display a desired pattern on the surface of the resin molded product 1.

In the manufacturing method of this embodiment, the plurality of depressions 3 are arranged in parallel to each other to form a laminated pattern, so it is particularly effective for suppressing pattern disorder.

Moreover, in the manufacturing method of this embodiment, the pattern-forming resin composition 4 injected into the plurality of depressions 3 is changed by the first depressions 3a and the second depressions 3b, so that it can be easily diversified on the surface of the resin molded product 1. To display the pattern pattern.

In the manufacturing method of the present embodiment, the resin composition 4 for forming a pattern formed by forming a plurality of protrusions 11 has a higher heat resistance than that of the resin composition 5 for a base forming the base 10 Resin composition. With this, when the resin molded product 1 is used as a kitchen worktop 12, even if the high temperature Conditioning containers such as pans or pots in a state are directly placed on the kitchen workbench 12, and it is not easy to cause undesirable conditions such as discoloration of the upper surface of the kitchen workbench 12.

Moreover, in the manufacturing method of this embodiment, since the plurality of protrusions 11 are formed into a triangular cross-section, when the resin molded product 1 is used as a kitchen worktop 12, it is possible to suppress contact with the conditioning container in a high temperature state. area. Therefore, the traces of the conditioning container are not easily attached to the upper surface of the kitchen worktop 12.

Furthermore, in the manufacturing method of this embodiment, since the plurality of protrusions 11 protrude by 50 μm or more, even if the conditioning container in a high temperature state is mounted on the plurality of protrusions 11, it is possible to move from the conditioning container to the base 10 The distance is ensured to a certain level, and it is not easy to cause problems such as discoloration of the base portion 10 due to heat.

Furthermore, in the manufacturing method of this embodiment, the plural protrusions 11 slightly protrude with a size of 50 μm or more and 400 μm or less, so the part 101 between the adjacent protrusions 11 is less likely to contain dirt.

In addition, in the resin molded article 1, since a plurality of protrusions 11 protrude from the surface 100 of the base portion 10, shadows are easily generated on the surface of the resin molded article 1 when light is irradiated, and patterns are easily displayed effectively.

1-5. Modifications

Next, a modification example of the above-mentioned manufacturing method and the resin molded product 1 will be described.

The plurality of recesses 3 are not limited to those arranged in parallel with each other with spaces to form a laminated pattern, but may also be arranged to form patterns other than the laminated pattern. For example, the plurality of recesses 3 may include recesses 3 extending in a direction crossing the opposite direction D1, and may also include recesses 3 intersecting each other.

In addition, each of the plurality of depressions 3 is not limited to grooves extending in one direction (meaning that they are connected into a two-dimensional linear groove). Dot-shaped recesses), or a combination thereof.

The resin composition 4 for pattern formation injected into each of the plural recesses 3 may be the same as each other. The plurality of recesses 3 may also include the recesses 3 injected by the resin composition 5 for the base.

The cross section orthogonal to the longitudinal direction of each of the plurality of depressions 3 may be a shape other than a triangle, for example, a semicircle, a semiellipse, or the like.

The resin composition 4 for pattern formation may be a resin composition having the same heat resistance as that of the resin composition 5 for a base.

The resin molded product 1 is not limited to the kitchen console 12, and may also constitute the top plate of the wash and dresser, the base installed under the faucet in the bathroom, sink, bathtub, and other items.

2. Implementation form 2

Next, the manufacturing method of Embodiment 2 shown in FIGS. 6A to 6D will be explained. Hereinafter, with respect to the manufacturing method of this embodiment, the difference from the manufacturing method of Embodiment 1 is demonstrated in detail. In the manufacturing method of this embodiment, the pattern injection step and the pattern hardening step are different from the manufacturing method of the first embodiment.

In the pattern injection step of this embodiment, the resin composition 4 for pattern formation is injected into the plural recesses 3 and the peripheral portions of the plural recesses 3. In this embodiment, the injection of the resin composition 4 for pattern formation toward the peripheral part of the plurality of depressions 3 is performed using the resin composition 4 for pattern formation that overflows from the plurality of depressions 3.

In detail, in the pattern injection step, as shown in FIG. 6A, first, the resin composition 4 for pattern formation is injected into the plurality of depressions 3 by an amount slightly exceeding the volume of each depression 3. Next, the pattern-forming resin composition 4 injected into each depression 3 is spread with a scoop or the like along the longitudinal direction of each depression 3. As a result, as shown in FIG. 6B, a part of the pattern forming resin composition 4 is expanded and laminated to the peripheral portion of the plurality of depressions 3 (that is, the portion of the portion 211 adjacent to the depression 3 ). In the peripheral portion of the plurality of depressions 3, the resin composition 4 for pattern formation having a smaller thickness in the vertical direction than the resin composition 4 for pattern formation in each depression 3 is laminated. The thickness of the pattern forming resin composition 4 laminated on the peripheral portion of the plurality of depressions 3 is, for example, about 1 mm.

Next, the pattern hardening step hardens the pattern forming resin composition 4 that has been injected into the plurality of depressions 3 and the peripheral portions of the plurality of depressions 3. The hardening of the resin composition 4 for pattern formation is performed by heating the lower mold 2a with a heating device in the same manner as in the first embodiment.

Next, in the manufacturing method of this embodiment, as shown in FIG. 6C, the base forming step similar to that of the first embodiment is performed.

Using the manufacturing method of this embodiment described above, the resin molded product 1 as shown in FIG. 6D can be manufactured. In this resin molded product 1, the pattern formed by the resin composition 4 for pattern formation can be displayed on the peripheral portions of the plurality of projections 11 and each projection 11 in the surface 100, and the boundary of the projections 11 can be blurred and displayed. Shows a more natural pattern.

In addition, in the pattern injection step, the pattern forming resin composition 4 is injected toward the peripheral portion of the plurality of recesses 3, and a part of the pattern forming resin composition 4 overflowing from each recess 3 can also flow out to each recess due to its own weight. 3 to the peripheral part. In addition, the injection of the resin composition 4 for pattern formation toward the peripheral portion of the plurality of depressions 3 can also be performed by adjusting the injection amount to be less than the injection amount toward each depression 3 by an automatic coater or the like. In addition, the injection amount of the resin composition 4 for pattern formation toward each recess 3 and its peripheral part may be the same as each other.

3. Implementation Mode 3

Next, the manufacturing method of Embodiment 3 shown in FIGS. 7A to 8A and 8B will be described. Hereinafter, the manufacturing method of the present embodiment will be described in detail with respect to the parts that are different from the manufacturing method of the first embodiment. In the manufacturing method of this embodiment, the pattern injection step, the pattern hardening step, and the base forming step are respectively different from the manufacturing method of the first embodiment. In the manufacturing method of this embodiment, the plurality of depressions 3 are grooves extending in one direction.

In the pattern injection step of the present embodiment, the resin composition 4 for forming a pattern is injected into a part of the longitudinal direction of each of the depressions 3 with respect to the plurality of depressions 3.

In detail, the pattern injection step of the present embodiment, as shown in FIGS. 7A and 8A, is for plural depressions 3, while winding along the longitudinal direction of each depression 3, straddling each depression 3 many times and aligning While injecting the resin composition 4 for pattern formation. Thereby, in the pattern injection step of this embodiment, the resin composition 4 for pattern formation is injected into only a part of the longitudinal direction of each recessed 3rd. In addition, FIG. 7A is a cross-sectional view taken along the line C-C of FIG. 8A. In the remaining part other than the aforementioned part in the longitudinal direction of each recess 3, a non-pattern injection region 30 in which the resin composition 4 for pattern formation is not directly injected is formed.

Next, in the pattern injection step of this embodiment, the resin composition 4 for pattern formation injected into each recess 3 and its peripheral portion is spread with a scoop or the like along the longitudinal direction of each recess 3. As a result, as shown in FIGS. 7B and 8B, in the peripheral portion of the plurality of recesses 3 (that is, the portion adjacent to the recess 3 in the portion 211), a part of the pattern-forming resin composition 4 is expanded to thin the thickness Cascade. In addition, Fig. 7B is a cross-sectional view taken along the line C-C of Fig. 8B.

Next, the pattern hardening step of this embodiment hardens the pattern-forming resin composition 4 injected into a part of the longitudinal direction of each recess 3. In the pattern hardening step, as in the first embodiment, the lower mold 2a of the heating mold 2 is used to harden the pattern forming resin composition 4 that has been injected into the depressions 3. At this time, the pattern-forming resin composition 4 injected into the peripheral portion of each recess 3 is also hardened.

Next, as shown in FIG. 7C, in the base forming step, the base resin composition 5 is injected into the mold 2 so as to cover the molding surface 20, and the base resin composition 5 is injected into each depression 3 for the plurality of depressions 3 The remaining part other than the aforementioned part in the longitudinal direction. Thereby, the non-pattern injection area 30 of the mold groove 23 and the plural recesses 3 is filled with the resin composition 5 for a base.

Next, in the base forming step, the upper mold 2b and the lower mold 2a of the heating mold 2 are used to harden the entire base resin composition 5. Thereby, the resin composition 5 for a base filled in the non-pattern injection area 30 of the cavity 23 and the plural recesses 3 is hardened.

Using the manufacturing method of the third embodiment described above, the resin molded product 1 shown in FIG. 7D can be manufactured. In this resin molded product 1, the pattern displayed by the plurality of protrusions 11 can be changed by the part where the pattern forming resin composition 4 is injected and the part that is not injected, so that uneven patterns can be displayed and displayed more Natural patterns.

In addition, in the pattern injection step of the present embodiment, the resin composition 4 for pattern formation is injected toward a part of the longitudinal direction of each recess 3, for example, it can also be formed by intermittently injecting the pattern along the longitudinal direction of each recess 3. The resin composition 4 is used for this. At this time, in the same manner as in the second embodiment, the resin composition 4 for pattern formation may be poured into each recess 3 so as to overflow to the peripheral portion.

4. Embodiment 4

Next, the manufacturing method of Embodiment 4 will be explained. Hereinafter, with respect to the manufacturing method of this embodiment, the difference from the manufacturing method of Embodiment 1 is demonstrated in detail. In the manufacturing method of this embodiment, the flower The pattern injection step, the pattern hardening step, and the base forming step are respectively different from the manufacturing method of the first embodiment.

In the pattern injection step of this embodiment, the resin composition 4 for pattern formation containing a hardener is injected into the plurality of depressions 3. In the pattern hardening step, the pattern forming resin composition 4 injected into the plurality of depressions 3 is hardened by heating the mold 2. In the base forming step, after cooling the mold 2 to the injection temperature of the base resin composition 5, the base resin composition 5 is injected.

The resin composition 4 for pattern formation used in the manufacturing method of this embodiment has radical polymerization type thermosetting resins, such as acrylic resin and unsaturated polyester resin.

The unsaturated polyester resin is a thermosetting resin obtained by dehydration condensation of a polybasic acid component with an unsaturated polybasic acid as an essential component, a glycol component and/or an epoxy compound component.

The polybasic acid component is a compound having a substituent that can react with the hydroxyl group of the diol component or the epoxy group of the epoxy component to form an ester bond. The polybasic acid component is an unsaturated polybasic acid having two or more substituents as an essential component, and a saturated polybasic acid or a monovalent acid can also be used as a part thereof. Examples of unsaturated polybasic acids include maleic acid, fumaric acid, aconitic acid, itaconic acid, anhydrides of these acids, and derivatives (halides, etc.) of these acids, and these can also be used in combination More than two types.

As far as glycol components are concerned, examples include ethylene glycol, propylene glycol, dipropylene glycol, butylene glycol, triethylene glycol, neopentyl glycol, trimethylene glycol, glycerin, hydrogenated bisphenol A, bisphenol A, and bisphenol A. Phenol S, etc., can also be used in combination of two or more types.

The epoxy component may be exemplified by ethylene oxide, propylene oxide, etc., and two or more of these may be used in combination.

As far as the unsaturated monomer is concerned, it is sufficient as long as it can be copolymerized with the above-mentioned unsaturated polyester. Unsaturated monomers include styrene, vinyl toluene, vinyl acetate, diallyl phthalate, triallyl cyanurate, methyl acrylate, methacrylate, methyl Methyl acrylate, etc., can also be used in combination of two or more types.

As for the hardener, examples include methyl ethyl ketone peroxide, tertiary butyl peroxide-2-ethylhexanoate, benzyl peroxide, and di(tertiary butyl)peroxide 3,3,5-trimethyl Cyclohexane, tertiary butyl peroxybenzoate, dicumyl peroxide, tertiary butyl hydroperoxide, etc.

The resin composition 4 for pattern formation may contain inorganic fillers, viscosity reducers, defoamers, internal release agents, antifouling agents, ultraviolet absorbers, colorants, pattern materials, etc., as required. As for the inorganic filler, for example, calcium carbonate, aluminum hydroxide, silicon dioxide, aluminum oxide, glass beads, etc. are mentioned. The addition amount of the inorganic filler is preferably 20 to 600 parts by weight of the entire resin composition 4 for pattern formation.

The resin composition 4 for pattern formation has the same coloring agent as the coloring agent which the resin composition 4 for pattern formation of Embodiment 1 has.

In the pattern hardening step of the present embodiment, the lower mold 2a of the heating mold 2 is used to harden the pattern forming resin composition 4 injected into the plurality of depressions 3. The lower mold 2a is heated to a temperature (for example, 70°C) for causing the resin composition 4 for pattern formation to undergo a curing reaction.

The base forming step of this embodiment includes a cooling step of cooling the lower mold 2a of the mold 2 to the injection temperature of the base resin composition 5 (that is, the temperature at which the base resin composition 5 does not undergo a curing reaction). After this cooling step, the resin composition 5 for the base is injected into the mold 2 (2a, 2b) so as to cover the molding surface 20. After the resin composition 5 for a base is injected, the mold 2 (2a, 2b) is heated to harden the resin composition 5 for a base.

The resin composition 5 for a base has a thermosetting resin of the same kind as that of the resin composition 4 for pattern formation.

In the manufacturing method of the present embodiment described above, since the resin composition 4 for pattern formation is chemically cured, an insufficiently cured state can be prevented. Thereby, the manufacturing method of the present embodiment can prevent the pattern-forming resin composition 4 in an insufficiently cured state from chemically reacting with the resin composition 5 for the base when the resin composition 5 for the base is injected It melts and spreads the pattern of the resin composition 4 for pattern formation to an unexpected part. The manufacturing method of this embodiment can be combined with the manufacturing method of Embodiment 2 or 3. The manufacturing method of this embodiment is the same as the manufacturing method of the second embodiment, and there are cases in which a resin composition 4 for forming a pattern with a thin thickness is laminated on the peripheral portion of each recess 3. The resin composition 4 for forming a pattern with a thin thickness is hindered by the oxygen in the air to harden the reaction, and it is not easy to harden sufficiently. However, in the manufacturing method of this embodiment, the thin-thickness resin composition 4 for pattern formation can also be fully hardened by the pattern hardening step.

Furthermore, in the manufacturing method of this embodiment, since the base forming step includes a cooling step, the resin composition 5 for the base can be prevented from being injected into the lower mold 2a of the mold 2 in a high temperature state, and the resin composition 5 for the base can be prevented from being injected. It causes a hardening reaction immediately after injection.

Moreover, in the manufacturing method of this embodiment, since the resin composition for base 5 and the resin composition 4 for pattern formation have the same kind of thermosetting resin, the resin composition for base 5 is chemically bonded to the resin composition 4 for pattern formation, so interfacial peeling is unlikely to occur.

5. Implementation Mode 5

Next, the manufacturing method of Embodiment 5 will be explained. Hereinafter, with respect to the manufacturing method of this embodiment, the difference from the manufacturing method of Embodiment 1 is demonstrated in detail.

In the manufacturing method of this embodiment, the pattern-forming resin composition 4 contains a particulate pattern material as a coloring agent, and does not contain pigments, dyes, or pigments that are different from the pigments, dyes, or a combination of the base resin composition 5, Dyes, or combinations thereof.

In this embodiment, the resin composition 5 for a base is a thermosetting resin containing a curing agent. The base resin composition 5 has a viscosity of 50Pa. The fluidity below s can be injection molded.

As the thermosetting resin of the resin composition 5 for a base, radical-curable resins such as unsaturated polyester resins and acrylic resins, epoxy resins, urethane resins, and the like are exemplified. In addition, as the thermosetting resin of the resin composition 5 for a base, other types of thermosetting resins may also be used.

Acrylic resin, methacrylic acid/acrylic acid or unsaturated monomers with esters such as these as the main component, and polymers with unsaturated monomers dissolved in them. The main components of unsaturated monomers include methacrylic acid, methyl methacrylate, ethyl methacrylate, butyl methacrylate, 2-hydroxyethyl methacrylate, and glycidyl methacrylate. Ester, acrylic acid, methyl acrylate, ethyl acrylate, butyl acrylate, 2-ethylhexyl acrylate, TMPTA (trimethylolpropane triacrylate), etc.

In the case of the thermosetting resin radical-curable resin of the resin composition 5 for a base, as the curing agent, the curing agent of Embodiment 4 is exemplified as an example.

The base resin composition 5 may contain inorganic fillers, viscosity reducers, defoamers, internal release agents, antifouling agents, and ultraviolet absorbers as needed. The addition amount of the inorganic filler is preferably 20 to 600 parts by weight of the entire base resin composition 5.

The resin composition 4 for pattern formation has a thermosetting resin of the same curing system as the thermosetting resin of the resin composition 5 for a base. For example, in the case of the unsaturated polyester resin of the thermosetting resin-based radical-curing resin of the resin composition 5 for base, the thermosetting resin-based radical-curing resin of the resin composition 4 for pattern formation is unsaturated polyester resin or acrylic Resin. In this case, as for the thermosetting resin of the resin composition 4 for pattern formation, epoxy resins or urethane resins of different curing systems cannot be used.

With regard to the coloring agent contained in the resin composition 4 for pattern formation, the material of the granular pattern material is exemplified by polyester resin, acrylic resin, PET (polyethylene terephthalate) film, mica, silica powder, Natural sand, etc. The grain size of the pattern material is 0.05mm~5mm, more preferably 0.1~1mm. The color of the granular pattern material is different from that of the resin composition 5 for the base. The addition amount of the particulate pattern material is 1 to 50 vol% of the entire resin composition 4 for pattern formation, and more preferably 5 to 10 vol%.

The resin composition 4 for pattern formation, as far as the colorant is concerned, besides the granular pattern material, it can also be provided with the same pigment, dye, or combination as the resin composition 5 for the base in the following manner: and the resin for the base The addition amount in the composition 5 is equal to or less.

In addition, in the resin composition 4 for pattern formation, as long as the addition amount of the coloring agent other than the particulate pattern material is 0.2% or less in terms of the total solid content of the resin composition 4 for pattern formation, it may have the same The coloring agent of the resin composition 5 for a base is a different coloring agent. This is because when the total amount of the coloring agent of the resin composition 4 for pattern formation is small, the color shift of each production lot of the resin composition 4 for pattern formation is conspicuous, so a small amount of toner is added to suppress This color cast.

The resin composition 4 for pattern formation may contain an inorganic filler, a viscosity reducer, a defoamer, an internal release agent, an antifouling agent, and an ultraviolet absorber according to needs.

The molding surface 20 of the lower mold 2a of the mold 2 used in the manufacturing method of this embodiment is a rough surface with Ra (arithmetic mean roughness) of 5 μm or more and 500 μm or less.

The manufacturing method of this embodiment uses the above-mentioned pattern forming resin composition 4 and base resin composition 5, and performs the same pattern injection step, pattern hardening step, and base forming step as in the first embodiment to produce a resin molded product 1.

In the manufacturing method of the present embodiment, the pattern-forming resin composition 4 contains a particulate pattern material as a colorant. Therefore, when the resin composition 5 for a base is injected, the particulate pattern material is not easy to be chemically dissolved. In addition, the granular pattern material does not easily flow out because it is physically caught on the rough surface of the molding surface 20. Furthermore, even when part of the granular pattern material flows out, the granular pattern material is not easy to dissolve. Therefore, compared with the case where the pigment or dye flows out, the resin composition 4 for pattern formation can be suppressed from deteriorating. The colors flow out in a wide range.

The manufacturing method of this embodiment described above can be combined with the manufacturing methods of the second to fourth embodiments.

In addition, the manufacturing method of the present embodiment may also be a method of manufacturing the resin molded product 1 by using a mold 2 that does not have a plurality of depressions 3 on the molding surface 20. In this case, the resin composition 4 for pattern formation is injected into the molding surface 20 of the rough surface of the lower mold 2a and hardened, and thereafter, the resin composition 5 for the base is injected into the molds 2a, 2b and made Harden to produce resin molded product 1. In this case, when the resin composition 5 for a base is injected, the color of the resin composition 4 for pattern formation may be prevented from flowing out in a wide range.

6. Embodiment 6

Next, the manufacturing method of the sixth embodiment will be described. Hereinafter, with respect to the manufacturing method of this embodiment, the difference from the manufacturing method of Embodiment 1 is demonstrated in detail.

In the manufacturing method of the present embodiment, the molding surface 20 is a rough surface having a plurality of recesses 6 that are shallower than the plurality of recesses 3 (refer to FIGS. 9A and B). The resin composition 5 for a base contains a particulate pattern material.

The depth of each of the plurality of recesses 6 is 10 μm or more and 1 mm or less. The molding surface 20 contains a rough surface with a gloss level of 65 or less and 40 or more.

In the base resin composition 5, at least two types of granular pattern materials are different in color and have a particle size of 700 μm or less and 50 μm or more, relative to the ratio of the entire granular pattern material of the base resin composition 5 Department is above 20% and below 80%.

In detail, the resin composition 5 for a base includes: the same thermosetting resin as in the first embodiment; at least two types of particulate pattern materials as colorants; and pigments, dyes, or dyes as colorants Its combination. At least two types of granular pattern materials have different colors from the pigments, dyes, or combinations thereof contained in the resin composition 5 for the base.

The granular pattern material has a particle size of 700 μm or less (in other words, 25 mesh or less) 10 μm or more. When the particle size is greater than 700 μm, the granular pattern material is easily recognized as particles.

The ratio of at least two types of granular pattern materials to the entire base resin composition 5 is 1 vol% or more and 70 vol% or less, and more preferably 2 vol% or more and 60 vol% or less in total.

At least two types of granular pattern materials are, for example, two types of granular patterns with different colors from each other, and more preferably three or more types of granular pattern materials with different colors from each other.

The ratio of at least two types of particulate pattern materials to the entire particulate pattern material of the base resin composition 5 is 20% or more and 80% or less.

9A to C show an example of the mold 2 used in the manufacturing method of this embodiment. The molding surface 20 of the lower mold 2a of the mold 2 is formed with an etching surface 20a formed by etching and a sandblasting surface 20b formed by sandblasting.

The etching surface 20a is formed with a plurality of recesses 6 having a depth of 10 μm or more and 1 mm or less in a pattern. The blasting surface 20b is formed with small irregularities at random arrangement and depth, so that the blasting surface 20b becomes a rough surface with a glossiness of 65 or less and 40 or more as measured by the 60-degree measurement method.

In this embodiment, part of the part 211 between the adjacent recesses 3 in the molding surface 20 of the lower mold 2a is formed with an etching surface 20a, and the other part of the part 211 is formed with a sandblasting surface 20b. The etching surface 20a and the sandblasting surface 20b are integrally provided in the part 211.

In the manufacturing method of the present embodiment, the lower mold 2a of the mold 2 described above is used to perform the pattern injection step, the pattern hardening step, and the base forming step of the first embodiment, so that the resin molded product 1 is manufactured. The manufacturing method of this embodiment uses the resin composition 4 for pattern formation similar to Embodiment 1 and the resin composition 5 for the said base.

In the surface 100 of the resin molded product 1, the part formed by the etching surface 20a is formed with a plurality of convex portions having a height of 10 μm or more and 1 mm or less. Therefore, because this part of the light is diffused, the shape of the granular pattern material contained in this part appears uneven and slightly distorted.

In the surface 100 of the resin molded product 1, the part formed by the sandblasting surface 20b becomes a rough surface and the gloss is reduced. Therefore, the outline of the granular pattern material contained in this part is blurred. The plural granular pattern materials located at adjacent positions are shown as continuous fuzzy outlines, and shown as being colored as a whole.

Here, the resin molded product 1 of the present embodiment contains at least two types of granular pattern materials, and therefore, among the portions containing one type of granular pattern materials to a large extent, this kind of granular pattern materials The style is distorted or blurred, and only the colors are displayed. In addition, in the resin molded product 1 of this embodiment, Among the parts that contain another type of granular pattern material to a large extent, the pattern of this other type of granular pattern material is distorted or blurred, and only the color is displayed.

Thereby, in the resin molded product 1 of the present embodiment, at least two types of granular pattern materials show only the color on the surface, and it is easier to display uneven natural patterns.

In addition, the manufacturing method of this embodiment can also be combined with the manufacturing methods of Embodiments 2 to 5.

7. Other

The manufacturing method of the sixth embodiment can also be a modified example as shown in Figs. 10A to C, in which only the resin composition 5 for the base is injected into the mold 2 that does not have plural depressions 3 on the molding surface 20 to harden it, thereby A method of manufacturing a resin molded product 1.

That is, the manufacturing method of the modified example is a method of manufacturing the resin molded product 1 of the resin molded product 1 by using a mold 2 base having a plurality of recesses 6 having a depth of 10 μm or more and 1 mm or less on the molding surface 20. The manufacturing method of the modification includes a base forming step of injecting the base resin composition 5 into the mold 2 so as to cover the molding surface 20 and hardening it. The resin composition 5 for a base contains a particulate pattern material.

In more detail, the resin composition 5 for a base includes at least two types of granular pattern materials, and at least two types of granular pattern materials are different in color and have a particle size of 700 μm or less and 50 μm or more. The ratio of the entire particulate pattern material possessed by the resin composition 5 is 20% or more and 80% or less.

In the manufacturing method of the modification example, at least an etching surface 20a formed by etching is formed on the molding surface 20. Preferably, the forming surface 20 is further formed with a sandblasting surface 20b formed by sandblasting, but the sandblasting surface 20b may not be formed.

The resin composition 5 for a base used in the manufacturing method of the modification is the same as the resin composition 5 for a base used in the manufacturing method of the sixth embodiment. In addition, in the manufacturing method of the modified example, the mold 2 does not have a plurality of depressions 3, so the resin composition 4 for pattern formation is not used.

The manufacturing method of the above modification example is also the same as the manufacturing method of the sixth embodiment. At least two types of granular pattern materials are displayed only in color on the surface, and it is possible to manufacture a resin molded product that is easier to display uneven natural patterns. 1.

8. Summary

As in the manufacturing methods of Embodiments 1 to 6 and their modifications described above, the manufacturing method of the first aspect has the following configuration.

That is, the manufacturing method of the first aspect is a method of manufacturing a resin molded product (1) by using a mold (2) having a plurality of depressions (3) on the molding surface (20). The manufacturing method includes a pattern injection step, a pattern hardening step, and a base forming step. In the pattern injection step, the resin composition (4) for pattern formation is injected into the plurality of depressions (3). The pattern hardening step hardens the pattern-forming resin composition (4) that has been injected into the plurality of depressions (3). In the base forming step, a base resin composition (5) having a different composition from the pattern forming resin composition (4) is injected into the mold (2) to cover the molding surface (20) and cured.

As with the above configuration, the manufacturing method of the first aspect is to inject the resin composition (5) for the base in a state where the resin composition (4) for pattern formation is arranged in each recess (3). Therefore, the manufacturing method of the first aspect can prevent the resin composition for pattern formation (4) from shifting due to the injection of the resin composition (5) for the base, causing the pattern to be disordered. Thereby, the manufacturing method of the first aspect can easily display the desired pattern on the surface of the resin molded product (1).

Also, like the manufacturing methods of the above-mentioned Embodiments 1 to 6 and their modifications, the manufacturing method of the second aspect has the following structure in addition to the structure of the manufacturing method of the first aspect.

That is, in the manufacturing method of the second aspect, the pattern injection step injects the pattern forming resin composition (4) into the plurality of depressions (3) and the peripheral portions of the plurality of depressions (3).

In the resin molded product (1) manufactured by the second aspect of the manufacturing method having the above-mentioned structure, the pattern formed by the resin composition (4) for pattern formation is shown in the plural number of depressions (3) The protrusion (11) and its surrounding parts. Thereby, in the resin molded article (1) manufactured by the manufacturing method of the second aspect, the boundary of each protrusion (11) can be blurred and displayed on the surface with a more natural pattern.

Also, like the manufacturing methods of the above-mentioned Embodiments 1 to 6 and their modifications, the manufacturing method of the third aspect has the following structure in addition to the structure of the manufacturing method of the first or second aspect.

That is, in the manufacturing method of the third aspect, the plural recesses (3) are grooves extending in one direction, respectively. In the pattern injection step, the resin composition (4) for forming a pattern is injected into a part of the longitudinal direction of each of the depressions (3) for the plurality of depressions (3). In the substrate forming step, the resin composition (5) for the substrate is injected into the mold (2) to cover the molding surface (20), and the resin composition (5) for the substrate is injected into each of the depressions (3). The remaining part of the recess (3) other than the aforementioned part in the longitudinal direction.

In the resin molded product (1) manufactured by the third aspect of the manufacturing method having the above-mentioned structure, the pattern displayed on the plural protrusions (11) formed by the plural recesses (3) can be injected with the pattern The part of the resin composition (4) used for formation and the part not injected are changed. Thereby, in the resin molded product (1) manufactured by the manufacturing method of the third aspect, uneven patterns can be displayed and a more natural pattern can be displayed on the surface.

Also, like the manufacturing methods of the above-mentioned Embodiments 1 to 6 and their modifications, the manufacturing method of the fourth aspect further has the following structure in addition to the structure of any one of the first to third aspects.

That is, in the pattern injection step of the manufacturing method of the fourth aspect, the pattern forming resin composition (4) containing a hardener is injected into the plurality of depressions (3). In the pattern hardening step, the mold (2) is heated to harden the pattern-forming resin composition (4) that has been injected into the plurality of depressions (3). In the base forming step, after cooling the mold (2) to the injection temperature of the base resin composition (5), the base resin composition (5) is injected.

The manufacturing method of the fourth aspect having the above-mentioned structure can heat and harden the pattern-forming resin composition (4) containing a hardener, thereby preventing: a hardening reaction in the pattern-forming resin composition (4) In an inadequate state, the resin composition (5) for the substrate is injected. Thereby, the resin molded article (1) manufactured by the manufacturing method of the fourth aspect can prevent the pattern of the resin composition (4) for pattern formation from spreading to unexpected parts. Furthermore, in the manufacturing method of the fourth aspect, since the substrate forming step includes a cooling step, the resin composition (5) for the substrate can be prevented from being injected into the mold (2) in a high temperature state, and the resin composition for the substrate can be prevented from being injected into the mold (2). (5) The hardening reaction is caused immediately after injection.

Also, like the manufacturing methods of the above-mentioned Embodiments 1 to 6 and their modifications, the manufacturing method of the fifth aspect has the following structure in addition to the structure of any one of the first to fourth aspects.

That is, in the manufacturing method of the fifth aspect, the pattern-forming resin composition (4) contains a particulate pattern material as a coloring agent, and does not contain the pigments and pigments contained in the base resin composition (5). The dye, or its combination is a different pigment, dye, or its combination.

In the manufacturing method of the fifth aspect having the above-mentioned constitution, the pattern-forming resin composition (4) has a granular pattern material as a colorant, so when the resin composition for a base (5) is injected, the granular pattern The material is not easy to be chemically dissolved, and the color of the resin composition for pattern formation (4) is not easy to flow out in a wide range.

Also, like the manufacturing methods of the above-mentioned Embodiments 1 to 6 and their modifications, the manufacturing method of the sixth aspect has the following structure in addition to the structure of any one of the first to fifth aspects.

That is, in the manufacturing method of the sixth aspect, the molding surface (20) is a rough surface having a plurality of recesses that are shallower than the plurality of recesses (3), and the resin composition for a base (5) contains particles Patterned wood.

In the resin molded product (1) manufactured by the sixth aspect of the manufacturing method having the above-mentioned configuration, the rough surface of the molded surface (20) can be used to form fine irregularities on the surface of the resin molded product (1) , Can diffuse light, or reduce gloss. Therefore, in the resin molded product (1) manufactured by the manufacturing method of the sixth aspect, the pattern of the granular pattern material of the base resin composition (5) can be blurred, and only the color can be displayed on the surface. It is easier to display uneven natural patterns.

Also, like the manufacturing methods of the above-mentioned Embodiments 1 to 6 and their modifications, the manufacturing method of the seventh aspect has the following structure in addition to the structure of the manufacturing method of the second aspect.

That is, in the manufacturing method of the seventh aspect, the resin composition (4) for pattern formation is injected toward the peripheral part of the plurality of depressions (3) by overflowing from the plurality of depressions (3). Resin composition (4) was performed.

In the manufacturing method of the seventh aspect having the above-mentioned structure, the resin composition (4) for pattern formation can be injected into the plurality of recesses (3) and their peripheral portions at the same time, and the injection work can be easily performed.

Moreover, as in the manufacturing methods of the above-mentioned Embodiments 1 to 6 and their modifications, the manufacturing method of the eighth aspect further has the following structure in addition to the structure of the manufacturing method of the third aspect.

That is, in the pattern injection step of the manufacturing method of the eighth aspect, for the plurality of depressions (3), one side meanders along the long side direction of each depression (3) and straddles each depression (3) many times. , And inject the pattern on one side Formation resin composition (4). Thereby, in the manufacturing method of the eighth aspect, the resin composition (4) for pattern formation is injected into a part of the longitudinal direction of each recess (3).

The manufacturing method of the eighth aspect with the above-mentioned structure is carried out by a simple injection method: the pattern displayed in the plural protrusions (11) formed by the plural recesses (3) is injected with resin for pattern formation The part of the composition (4) and the uninjected part are changed.

Moreover, as in the manufacturing methods of the above-mentioned Embodiments 1 to 6 and their modifications, the manufacturing method of the ninth aspect has the following structure in addition to the structure of the manufacturing method of the sixth aspect.

That is, in the manufacturing method of the ninth aspect, the depth of each of the plurality of recesses (6) is 10 μm or more and 1 mm or less.

In the manufacturing method of the ninth aspect having the above-mentioned structure, a plurality of recesses (6) formed on the molding surface (20) can be used to form tiny protrusions on the surface of the resin molded product (1) to make light Easy to diffuse. Therefore, in the resin molded product (1) manufactured by the manufacturing method of the ninth aspect, it is easy to display only the color of the granular pattern material of the resin composition (5) for the base on the surface, and it is easier to display uniformly. Natural pattern.

Also, like the manufacturing methods of the above-mentioned Embodiments 1 to 6 and their modifications, the manufacturing method of the tenth aspect has the following structure in addition to the structure of the sixth or ninth aspect of the manufacturing method.

That is, in the manufacturing method of the tenth aspect, the molding surface (20) contains a rough surface with a glossiness of 65 or less and 40 or more.

In the manufacturing method of the tenth aspect having the above-mentioned configuration, the surface of the resin molded product (1) can be formed with fine irregularities by forming a rough surface with a gloss level of 65 or less and 40 or more, and the gloss can be easily reduced. Therefore, in the resin molded product (1) manufactured by the manufacturing method of the tenth aspect, it is easy to display only the color of the granular pattern material of the resin composition for base (5) on the surface, and it is easier to display unevenness. Natural pattern.

Also, like the manufacturing methods of the above-mentioned Embodiments 1 to 6 and their modifications, the manufacturing method of the eleventh aspect, in addition to the configuration of any one of the sixth, ninth, and tenth aspects, further has the following述 Constitution.

That is, in the manufacturing method of the eleventh aspect, the resin composition (5) for a base contains at least two types of granular pattern materials. At least two types of granular pattern materials, which have different colors from each other, have a particle size of 700 μm or less and 50 μm or more, and have a ratio of 20% to 80% with respect to the total granular pattern material of the resin composition (5) for the base the following.

Among the resin molded articles (1) manufactured by the manufacturing method of the eleventh aspect with the above-mentioned configuration, at least two types of granular patterns and the patterns of the granular patterns are displayed in a blur, and only the colors can be displayed The surface is easier to show uneven natural patterns.

Also, like the manufacturing methods of the above-mentioned Embodiments 1 to 6 and their modifications, the manufacturing method of the twelfth aspect has the following structure in addition to the structure of any one of the first to eleventh aspects.

That is, in the manufacturing method of the twelfth aspect, the resin composition (4) for pattern formation includes a first resin composition (4a) and a second resin having a different composition from the first resin composition (4a) Composition (4b). The plurality of depressions (3) includes a first depression (3a) and a second depression (3b). The first resin composition (4a) is injected into the first recess (3a), and the second resin composition (4b) is injected into the second recess (3b).

The above-mentioned structure can be used to make the appearance of the two protrusions (11a, 11b) formed by the first recess (3a) and the second recess (3b) different from each other in the twelfth aspect of the manufacturing method. It is easy to achieve the diversification of the patterns displayed on the surface of the resin molded product (1).

Also, like the manufacturing methods of the above-mentioned Embodiments 1 to 6 and their modifications, the manufacturing method of the thirteenth aspect has the following structure in addition to the structure of any one of the first to twelfth aspects.

That is, in the manufacturing method of the thirteenth aspect, the plural recesses (3) are grooves extending in one direction, respectively. The cross section orthogonal to the longitudinal direction of each of the plurality of depressions (3) is triangular.

With the manufacturing method of the thirteenth aspect having the above-mentioned constitution, a resin molded product (1) can be manufactured, the surface of which has a plurality of protrusions (11) whose cross-section is triangular.

Also, like the manufacturing methods of the above-mentioned Embodiments 1 to 6 and their modifications, the manufacturing method of the fourteenth aspect has the following structure in addition to the structure of any one of the first to thirteenth aspects.

That is, in the manufacturing method of the fourteenth aspect, the resin composition for pattern formation (4) has higher heat resistance than the resin composition for base (5).

With the manufacturing method of the fourteenth aspect having the above-mentioned constitution, it is possible to manufacture a resin molded product (1) having a plurality of protrusions (11) with high heat resistance on the surface. Therefore, this resin molded product (1) has excellent heat resistance on the surface part, so it can be suitably used in kitchen counters (12), etc., where there is a concern that a hot pot or other conditioning container may be placed directly.

Also, like the manufacturing methods of the above-mentioned Embodiments 1 to 6 and their modifications, the manufacturing method of the fifteenth aspect has the following structure in addition to the structure of any one of the first to fourteenth aspects.

That is, in the manufacturing method of the fifteenth aspect, the resin molded product (1) constitutes a kitchen workbench (12).

With the above-mentioned configuration, in the fifteenth aspect of the manufacturing method, a desired pattern can be easily displayed on the surface of the kitchen counter (12), and a kitchen counter (12) with excellent design can be manufactured.

In addition, like the resin molded product (1) of the above-mentioned Embodiments 1 to 6 and their modifications, the resin molded product (1) of the sixteenth aspect has the following configuration.

That is, the resin molded article (1) of the sixteenth aspect includes a base portion (10) and a plurality of protrusions (11) protruding from the surface (100) of the base portion (10). Plural protrusions (11) are made of resin composition for pattern formation (4) The base part (10) is formed using a resin composition (5) for a base that has a different composition from the resin composition (4) for pattern formation.

With the above-mentioned structure, the resin molded product (1) of the sixteenth aspect can three-dimensionally display the pattern formed by the plural protrusions (11), and effectively display the desired pattern.

As mentioned above, the present invention has been described based on the embodiments shown in the attached drawings. However, the present invention is not limited to the above-mentioned embodiments, and suitable design changes can be made as long as it is within the scope of the present invention.

1: Resin molded product

2: Mould

2a: Lower mold (mold)

2b: Upper die (mold)

3: sunken

3a: first depression

3b: second depression

4: Resin composition for pattern formation

4a: The first resin composition

4b: Second resin composition

5: Resin composition for substrate

10: base part

11: protrusion

11a: first protrusion

11b: second protrusion

20: forming surface

21: recess

22: recess

23: Mould slot

100: surface

210: Bottom

211: Part

Claims (16)

A method for manufacturing a resin molded product, using a mold having a plurality of depressions on the molding surface to manufacture a resin molded product, includes: a pattern injection step, injecting a resin composition for pattern formation into the plurality of depressions; a pattern hardening step, The resin composition for pattern formation injected into the plurality of depressions is hardened; and the base forming step is to inject a resin composition for the base with a composition different from the resin composition for pattern formation into the mold to cover the molding surface. It hardens. The method for manufacturing a resin molded article of claim 1, wherein, in the pattern injection step, the pattern forming resin composition is injected into the plurality of depressions and the peripheral portion of the plurality of depressions. The method for manufacturing a resin molded article of claim 1, wherein the plurality of depressions are grooves extending in one direction, and in the pattern injection step, the resin composition for forming the pattern is injected into each of the plurality of depressions. In a part of the longitudinal direction of the recesses, in the substrate forming step, the resin composition for the substrate is injected into the mold to cover the molding surface to harden it, so that the resin composition for the substrate is injected into the plurality of recesses To the remaining part other than the part in the longitudinal direction of each recess. The method for manufacturing a resin molded article according to claim 1, wherein in the pattern injection step, the pattern forming resin composition containing a hardener is injected into the plurality of depressions, and in the pattern hardening step, the mold is heated, thereby The resin composition for pattern formation that has been injected into the plurality of depressions is cured, and the resin composition for the substrate is injected after the mold is cooled to the injection temperature of the resin composition for the substrate in the base forming step. The method for manufacturing a resin molded article of claim 1, wherein the resin composition for pattern formation contains a granular pattern material as a colorant, and does not contain any pigment, dye, or dye that the resin composition for a base has. Different combinations of pigments, dyes, or combinations thereof. The method for manufacturing a resin molded article according to claim 1, wherein the molded surface is a rough surface having a plurality of recesses shallower than the plurality of recesses, and the resin composition for the base has a granular pattern material. The method for manufacturing a resin molded article according to claim 2, wherein the resin composition for pattern formation is injected into the peripheral portion of the plurality of depressions by the resin composition for pattern formation that overflows from the plurality of depressions . Such as the method of manufacturing a resin molded product of claim 3, where: In the pattern injection step, the pattern forming resin composition is injected into the pattern forming resin composition while meandering along the longitudinal direction of each of the depressions many times across the depressions, so as to inject the pattern forming resin composition. The composition is injected into a part of the longitudinal direction of each recess. The method for manufacturing a resin molded article according to claim 6, wherein the plurality of recesses each have a depth of 10 μm or more and 1 mm or less. The method for manufacturing a resin molded article according to claim 6 or 9, wherein the molded surface includes a rough surface with a gloss of 65 or less and 40 or more. The method for manufacturing a resin molded article of claim 6, wherein the resin composition for a base includes at least two types of granular pattern materials, and the at least two types of granular pattern materials have different colors and particle diameters. The ratio of 700 μm or less to 50 μm or more with respect to the entire pattern material of the resin composition for a base is 20% or more and 80% or less. The method of manufacturing a resin molded article of claim 1, wherein the resin composition for pattern formation includes a first resin composition and a second resin composition having a composition different from the first resin composition, and the plurality of depressions It includes a first recess and a second recess. For the first recess, the first resin composition is injected, and for the second recess, the second resin composition is injected. The method for manufacturing a resin molded article of claim 1, wherein the plurality of depressions are grooves extending in one direction, and the cross section of each of the plurality of depressions orthogonal to the longitudinal direction is a triangle. The method for manufacturing a resin molded article according to claim 1, wherein the resin composition for forming a pattern has higher heat resistance than the resin composition for a base. The method for manufacturing a resin molded product of claim 1, wherein the resin molded product constitutes a kitchen workbench. A resin molded article comprising: a base part; and a plurality of protrusions protruding from the surface of the base part; and the plurality of protrusions are formed by using a resin composition for pattern formation, and the base part uses a composition system and the The base resin composition is formed with different resin compositions for pattern formation; the surface of the base part is rough, and the base resin composition has a granular pattern material.

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