JPH091766A - Natural stone-like composite molding body and manufacture thereof - Google Patents

Abstract

PURPOSE: To provide a natural stone-like composite molding body having excellent design and durability and high degree of freedom in shape, and a method for manufacturing it. CONSTITUTION: On a rear face of a covering material consisting of a resin molding which contains an organic filler and/or an inorganic filler, a backing material consisting of a resin having a composition different from that of the covering material is integrally adhered.

Description

【発明の詳細な説明】Detailed Description of the Invention

【０００１】[0001]

【産業上の利用分野】本発明は天然石調複合成形体及び
その製造方法に関する。さらに詳しく述べると樹脂成形
品よりなる表装材の裏面が、接着剤を介することなく、
表装材とは異なる組成の樹脂よりなる裏打ち材と接着一
体化した、意匠性、耐久性、形状の自由度に富んだ天然
石調複合成形体及びその製造方法に関する。BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a natural stone tone composite molding and a method for producing the same. More specifically, the back surface of the exterior material made of a resin molded product does not require an adhesive,
The present invention relates to a natural stone-like composite molded article that is adhesively integrated with a backing material made of a resin having a composition different from that of the facing material and has a high degree of freedom in design, durability and shape, and a method for producing the same.

【０００２】[0002]

【従来の技術】一般に、建材、内装材、住設品、調度品
等の分野では有機及び／又は無機フィラーを含有する各
種の樹脂成形品が使用されており、必要な強度を確保し
たり、厚みからくる重厚感を確保したりするため成形品
の厚みを厚くすることを要求されることが多い。このよ
うなものとして、大理石調、御影石調等、天然石のよう
な外観を有する樹脂成形品も知られている。同一材料で
前記の厚みを確保すると、該材料が高価な場合には成形
品の価格が上り経済的でなく、該材料の比重が高い場合
には成形品の重量が重くなり、また該材料に強度がない
場合には厚みを厚くしても成形品が必要な強度を保持し
えない等の問題があった。2. Description of the Related Art Generally, various resin molded products containing organic and / or inorganic fillers are used in the fields of building materials, interior materials, housing equipment, furniture, etc. to secure necessary strength, In many cases, it is required to increase the thickness of the molded product in order to secure a solid feeling due to the thickness. As such, a resin molded product having a natural stone-like appearance such as a marble tone or a granite tone is also known. If the thickness is secured with the same material, the price of the molded product rises when the material is expensive, which is not economical, and the weight of the molded product becomes heavy when the specific gravity of the material is high, and If there is no strength, there is a problem that the molded product cannot retain the required strength even if the thickness is increased.

【０００３】このような問題を解決する為、薄い樹脂成
形品を表装材として成形し、これと予め作っておいた基
板となる裏打ち材を、接着剤を用いて接着一体化するこ
とにより複合成形品とする方法も知られている。In order to solve such a problem, a thin resin molded product is molded as a covering material, and a preliminarily prepared substrate backing material is bonded and integrated with an adhesive to form a composite molding. It is also known how to make a product.

【０００４】しかしながらこの方法では、表装材と裏打
ち材を別に成形するため両者の形状を完全に一致させる
ことが困難であったり、これらを接着する場合、両者の
接着位置を合わせることが困難であり作業が煩雑であっ
たりするばかりでなく、接着面に両者の形状不適合によ
る隙間の生ずることが多く、衝撃強度の低下を引き起こ
すことが多い等、品質上の問題が多かった。しかも得ら
れた複合成形品は接着剤を介して表装材と裏打ち材とが
接着されている為、例えば加熱と冷却が繰り返えされる
様な過酷な環境下で使用する場合、耐久性の不足する傾
向があるという問題があった。また前記のような事情か
ら複雑な形状を有する複合成形品を作ることは困難であ
り、形状の自由度を制限されやすいという問題もあっ
た。However, according to this method, it is difficult to completely match the shapes of the fronting material and the backing material separately, and it is difficult to match the bonding positions of the two when bonding them. Not only the work is complicated, but there are many quality problems such as a gap often being generated on the adhesive surface due to a shape mismatch between the two, and a decrease in impact strength in many cases. Moreover, since the obtained composite molded article has the surface material and the backing material bonded together via an adhesive, it lacks durability when used in a harsh environment where heating and cooling are repeated, for example. There was a problem that there was a tendency to do. Further, from the above-mentioned circumstances, it is difficult to produce a composite molded article having a complicated shape, and there is a problem that the degree of freedom of the shape is likely to be limited.

【０００５】[0005]

【発明が解決しようとする課題】従って、本発明は、か
かる従来技術の有する種々の問題を解決して、意匠性、
耐久性に優れ、形状の自由度に富んだ天然石調複合成形
体及びその製造方法を提供することを目的とする。SUMMARY OF THE INVENTION Therefore, the present invention solves various problems of the prior art to improve designability,
An object of the present invention is to provide a natural stone-like composite molded article having excellent durability and a high degree of freedom in shape and a method for producing the same.

【０００６】[0006]

【課題を解決するための手段】本発明者らは、前記解決
すべき課題について鋭意検討した結果、各用途に必要な
意匠性、性能を有する樹脂成形品を表装材として成形
し、該表装材の裏面に表装材とは異なる組成の樹脂組成
物を配し、該組成物を硬化せしめるとともに表装材と接
着一体化させることにより、複雑な形状であっても表装
材と裏打ち材との隙間を生じない天然石調複合成形体が
簡便容易に得られることを見出し、本発明を完成した。Means for Solving the Problems As a result of intensive studies on the above problems to be solved, the present inventors formed a resin molded product having a design property and performance required for each use as a surface mounting material, A resin composition having a composition different from that of the surface covering material is arranged on the back surface of the sheet, and the composition is cured and bonded and integrated with the surface covering material, so that a gap between the surface covering material and the backing material is formed even in a complicated shape. The present invention has been completed by finding that a natural stone-like composite molded body that does not occur can be simply and easily obtained.

【０００７】すなわち、上記目的は本発明によれば、有
機フィラー及び／又は無機フィラーを含有する樹脂成形
品よりなる表装材の裏面に、表装材とは異なる組成の樹
脂よりなる裏打ち材を接着一体化している天然石調複合
成形体により達成される。That is, according to the present invention, the above object is to integrally bond a backing material made of a resin having a composition different from that of the surface mounting material to the back surface of the surface mounting material made of a resin molded product containing an organic filler and / or an inorganic filler. This is achieved by the natural stone-like composite molded body.

【０００８】また、上記目的は本発明によれば、有機フ
ィラー及び／又は無機フィラーを含有する樹脂成形品よ
りなる表装材の裏面に、表装材とは異なる組成の樹脂組
成物を配し、該組成物を硬化せしめて裏打ち材を形成せ
しめるとともに、表装材と裏打ち材とを接着一体化させ
る天然石調複合成形体の製造方法により達成される。Further, according to the present invention, the above object is to arrange a resin composition having a composition different from that of the covering material on the back surface of the covering material made of a resin molded product containing an organic filler and / or an inorganic filler. This is achieved by a method for producing a natural stone-like composite molded body in which the composition is cured to form a backing material, and the facing material and the backing material are bonded and integrated.

【０００９】さらにまた、上記目的は本発明によれば、
表装材とは異なる組成の裏打ち材の表面に、表装材を形
成する有機フィラー及び／又は無機フィラーを含有する
樹脂組成物を配し、該組成物を硬化せしめて表装材を形
成せしめるとともに、表装材と裏打ち材とを接着一体化
させることを天然石調複合成形体の製造方法によっても
達成することができる。Furthermore, according to the present invention, the above object is
A resin composition containing an organic filler and / or an inorganic filler that forms a surface covering material is arranged on the surface of a backing material having a composition different from that of the surface covering material, and the composition is cured to form the surface covering material. Adhesive integration of the material and the backing material can also be achieved by the method for producing a natural stone-like composite molded body.

【００１０】以下、本発明を詳細に説明する。Hereinafter, the present invention will be described in detail.

【００１１】本発明に用いられる表装材の樹脂成分とし
ては、種々の樹脂を使用することが可能であるが、得ら
れる複合成形体を建材、内装材、住設品、調度品等の分
野で使用する場合に要求される美麗性、耐久性等の点、
アクリル樹脂、不飽和ポリエステル樹脂、ビニルエステ
ル樹脂、ポリブチレンテレフタレート樹脂が好ましく、
これらの樹脂を組合わせて使うことも可能である。Various resins can be used as the resin component of the surface covering material used in the present invention. The resulting composite molded article is used in the fields of building materials, interior materials, housing equipment, furniture and the like. The points of beauty, durability, etc. required when used,
Acrylic resin, unsaturated polyester resin, vinyl ester resin, polybutylene terephthalate resin are preferable,
It is also possible to use these resins in combination.

【００１２】上記樹脂に配合される有機フィラーにおよ
び無機フィラーは、成形を阻害しないものであれば特に
制限はないが、例えば樹脂製粒子、合成繊維片等の有機
フィラー、水酸化アルミニウム、水酸化マグネシウム、
シリカ、アルミナ、炭酸カルシム、硫酸バリウム、岩石
粉、ガラス粉、陶磁器粉、雲母、タルク、ガラス繊維等
の無機フィラーを挙げることができ、これら幾つかのフ
ィラーを組み合わせて使用することによってより天然石
に近い外観とすることができる。The organic filler and the inorganic filler to be blended with the above-mentioned resin are not particularly limited as long as they do not hinder the molding. For example, resin particles, organic fillers such as synthetic fiber pieces, aluminum hydroxide, and hydroxide. magnesium,
Inorganic fillers such as silica, alumina, calcium carbonate, barium sulphate, rock powder, glass powder, ceramic powder, mica, talc and glass fiber can be mentioned. By using these fillers in combination, it becomes more natural stone. It can have a close appearance.

【００１３】有機フィラー及び／又は無機フィラーの添
加量は、樹脂１００重量部に対して通常３０〜８００重
量部、好ましくは５０〜３００重量部である。The amount of the organic filler and / or the inorganic filler added is usually 30 to 800 parts by weight, preferably 50 to 300 parts by weight, based on 100 parts by weight of the resin.

【００１４】本発明においては、有機フィラー及び／又
は無機フィラーを含有する樹脂を成形し、得られた成形
品を表装材として用いうるが、該樹脂には、各種染顔
料、紫外線吸収剤、光安定剤等の各種添加剤を含むこと
ができるし、さらに表装材の表面にハードコート層、塗
膜等の被覆層を施してもよい。In the present invention, a resin containing an organic filler and / or an inorganic filler may be molded and the obtained molded product may be used as a surface material. The resin may be various dyes and pigments, ultraviolet absorbers, light Various additives such as stabilizers may be contained, and a coating layer such as a hard coat layer or a coating film may be further provided on the surface of the facing material.

【００１５】本発明に用いる表装材は、例えば平板、２
次曲面や３次曲面を有する異形品などその形状、形態に
特に制限はなく、これらは種々の方法で成形することが
できるが、例えば 前記樹脂成分の原料となる重合性モノマー類、シラッ
プ等に前記有機フィラー及び／又は無機フィラー、その
他添加剤、重合開始剤等を混合してスラリー状にした
後、所定の形状を有する鋳型に注入・加熱して重合・硬
化する方法、 熱可塑性の樹脂成分を溶融し、これに有機フィラー及
び／又は無機フィラー、その他添加剤等を混合・混練し
た後、所定の形状を有する型に投入・冷却にて硬化する
方法（射出成形、プレス成形等）、 樹脂成分原料となる重合性モノマー類、シラップ類、
部分架橋ゲル状重合体から選ばれた少なくとも１つに、
有機フィラー及び／又は無機フィラー、その他添加剤、
重合開始剤等を混合・混練して得られる粘性の高い熱重
合性の樹脂組成物（以下コンパウンドということがあ
る）を金型等に投入し加圧加熱して重合・硬化する方法
等を挙げることができる。また板状の成形品を前記各方
法で一旦成形した後、これを例えば真空成形や加圧成形
等の２次加工で所定の形状に曲げる等の後加工すること
も可能である。The covering material used in the present invention is, for example, a flat plate or 2
There is no particular limitation on the shape or form of a deformed product having a quadric surface or a cubic surface, and these can be molded by various methods. For example, polymerizable monomers, syrup, etc., which are raw materials of the resin component, A method in which the organic filler and / or the inorganic filler, other additives, a polymerization initiator, etc. are mixed to form a slurry, which is then poured into a mold having a predetermined shape and heated to polymerize and cure, and a thermoplastic resin component. Melt, and then mix and knead the organic filler and / or inorganic filler, other additives, etc., and then put it into a mold having a predetermined shape and cure by cooling (injection molding, press molding, etc.), resin Polymerizable monomers, syrups, which are raw materials for ingredients,
At least one selected from the partially cross-linked gel polymer,
Organic filler and / or inorganic filler, other additives,
Examples include a method in which a highly viscous thermopolymerizable resin composition (hereinafter sometimes referred to as a compound) obtained by mixing and kneading a polymerization initiator and the like is charged into a mold or the like and heated and polymerized to cure under pressure. be able to. Further, it is also possible to carry out post-processing such as bending the plate-shaped molded product into a predetermined shape by secondary processing such as vacuum molding or pressure molding after it is once molded by each of the above methods.

【００１６】前記コンパウンドには、種々の樹脂の使用
が可能であるが、アクリル樹脂、不飽和ポリエステル樹
脂、ビニルエステル樹脂が好ましい。このようなコンパ
ウンドとして、例えば（メタ）アクリル酸エステル系重
合体と架橋性単量体を含んでいてもよい（メタ）アクリ
ル酸エステル系単量体を必須成分とする樹脂シラップと
有機フィラー及び／又は無機フィラー、重合開始剤等を
混合・混練したアクリル系コンパウンド、（メタ）アク
リル酸エステル系重合体を含んでいてもよい（メタ）ア
クリル酸エステル系単量体と架橋性単量体を必須成分と
する樹脂液を重合させ、該重合を途中で停止することに
より得られるアクリル系部分架橋ゲル状重合体に有機フ
ィラー及び／又は無機フィラー、重合開始剤等を配合・
混練したアクリル系コンパウンド、（メタ）アクリル酸
エステル系重合体を含んでいてもよい（メタ）アクリル
酸エステル系単量体と架橋性単量体を必須成分とする樹
脂液に少なくとも有機フィラー及び／又は無機フィラー
を配合して重合させ、該重合を途中で停止することによ
り得られるフィラー入りのアクリル系部分架橋ゲル状重
合体を混練したアクリル系コンパウンド、液状又はＢス
テージの不飽和ポリエステル樹脂又はビニルエステル樹
脂を必須成分とする樹脂組成物に有機フィラー及び／又
は無機フィラー、重合開始剤等を混合・混練した不飽和
ポリエステル系コンパウンド又はビニルエステル系コン
パウンド等を挙げることができる。Although various resins can be used for the compound, acrylic resins, unsaturated polyester resins and vinyl ester resins are preferable. As such a compound, for example, a resin syrup containing as an essential component a (meth) acrylic acid ester-based monomer which may contain a (meth) acrylic acid ester-based polymer and a crosslinkable monomer, an organic filler, and / or Alternatively, an inorganic compound, an acrylic compound obtained by mixing and kneading a polymerization initiator, and the like, which may contain a (meth) acrylic acid ester polymer, a (meth) acrylic acid ester monomer and a crosslinkable monomer are essential. An organic filler and / or an inorganic filler, a polymerization initiator, etc. are blended with an acrylic partially cross-linked gel polymer obtained by polymerizing a resin liquid as a component and stopping the polymerization halfway.
A kneaded acrylic compound, a (meth) acrylic acid ester-based monomer which may contain a (meth) acrylic acid ester-based polymer, and a resin liquid containing a crosslinkable monomer as essential components, at least an organic filler and / Alternatively, an acrylic compound, a liquid or a B-stage unsaturated polyester resin or vinyl obtained by kneading a filler-containing acrylic partially cross-linked gel polymer obtained by blending an inorganic filler and polymerizing the mixture and stopping the polymerization halfway An unsaturated polyester compound or a vinyl ester compound obtained by mixing and kneading an organic filler and / or an inorganic filler, a polymerization initiator and the like with a resin composition containing an ester resin as an essential component can be mentioned.

【００１７】特に好ましい態様に使用するアクリル系部
分架橋ゲル状重合体としては、特開昭６０−２０２１２
８号公報、特開昭６２−１７０５号公報、特開平２−２
９４３１１号公報、特開平３−５４２１７号公報等に記
載されている、部分架橋ゲル状重合体や多官能単量体を
変更する等これを改良した組成物等が用いられる。これ
らのうち、例えば架橋性単量体１〜６０重量％およびア
ルキルメタクリレートを主体としその重合体を溶融含有
していてもよい不飽和単量体９９〜４０重量％よりなる
混合物を部分重合して得られる組成物であって、該組成
物が８０重量％を越えない範囲で重合体を含有し、かつ
前記混合物中の重合体含有率よりも４〜６２重量％増加
させた部分架橋ゲル状重合体や、これらを破砕混練した
組成物や、前記重合体または破砕混練した組成物１００
重量部に対して、架橋性単量体を含有していてもよいア
ルキルメタクリレートを主体とする不飽和単量体又はそ
の重合体を溶解含有しているシラップ１〜１００重量部
を添加し、実質的に均一に混練し、流動性、浸透性等を
改良した組成物等が好ましく用いられる。The acrylic partially cross-linked gel polymer used in a particularly preferred embodiment is disclosed in JP-A-60-20212.
No. 8, JP-A-62-1705, JP-A No. 2-2
Compositions and the like described in Japanese Patent Application No. 94311 and Japanese Patent Application Laid-Open No. 3-54217, which are improved by partially changing the crosslinked gel polymer or polyfunctional monomer, and the like are used. Of these, for example, a mixture of 1 to 60% by weight of a crosslinkable monomer and 99 to 40% by weight of an unsaturated monomer which is mainly composed of an alkyl methacrylate and may contain the polymer in a molten state is partially polymerized. The composition obtained, wherein the composition contains a polymer in a range not exceeding 80% by weight, and the content of the polymer in the mixture is increased by 4 to 62% by weight. Coalescence, a composition obtained by crushing and kneading these, or the polymer or a composition obtained by crushing and kneading 100
To 1 part by weight, 1 to 100 parts by weight of syrup containing an unsaturated monomer mainly containing an alkyl methacrylate which may contain a crosslinkable monomer or a polymer thereof is added, A composition or the like that is uniformly kneaded uniformly and has improved fluidity and permeability is preferably used.

【００１８】以上のようにして種々の表装材が得られる
が、大理石、御影石、オパール等の天然石調の外観を有
する、アクリル系、不飽和ポリエステル系、ビニルエス
テル系、ポリブチレンテレフタレート系の樹脂成形品
（以下、人工大理石という）を好ましい例として挙げる
ことができる。Various surface covering materials can be obtained as described above, but acrylic, unsaturated polyester, vinyl ester and polybutylene terephthalate resin moldings having a natural stone appearance such as marble, granite and opal. Goods (hereinafter referred to as artificial marble) can be mentioned as preferable examples.

【００１９】人工大理石は意匠性等に優れ、近年内装
材、建材、住設機器等の分野で多く使われているが、高
価であるとともに高比重で重く、これを改良する為、薄
くすると脆弱となり割れ易くなる傾向があることから、
本発明の方法で、人工大理石の薄い表装材を成形し裏面
に例えばポリウレタン樹脂の発泡成形等で裏打ち材を成
形し表装材と接着一体化して複合成形体とすることによ
り、安価で軽く所望の強度を有する意匠性の高い成形品
を得ることができる。Artificial marble is excellent in design and has been widely used in the fields of interior materials, building materials, housing equipment, etc. in recent years, but it is expensive and has a high specific gravity and is fragile when thinned to improve it. Since it tends to crack easily,
By the method of the present invention, a thin artificial marble covering material is molded, and a backing material is molded on the back surface by, for example, foam molding of a polyurethane resin, and adhesively integrated with the covering material to form a composite molded body, which is inexpensive and lightly It is possible to obtain a molded product having strength and high designability.

【００２０】表装材の厚みは、最終的に得られる複合成
形体の表面外観を損なわない厚みであれが特に制限はな
いが、本発明の目的から薄い方が有利であり、０．５〜
１０ｍｍが好ましく、経済性、成形性の点から１〜５ｍ
ｍが特に好ましい。The thickness of the covering material is not particularly limited as long as it does not impair the surface appearance of the finally obtained composite molded body, but it is advantageous for the purpose of the present invention to be thin, 0.5-.
10 mm is preferable, and 1 to 5 m in terms of economical efficiency and moldability.
m is particularly preferred.

【００２１】また本発明の裏打ち材に用いられる樹脂
は、表装材との接着性が良く、最終的に得られる複合成
形品の要求する性能、即ち複合成形する事により単一材
料で厚い成形品を作った場合の、例えば経済性、重量、
強度等の欠点を改良する性能を有するものであれば特に
制限はないが、例えばアクリル樹脂、塩化ビニル樹脂、
ポリプロピレン樹脂等の熱可塑性樹脂、不飽和ポリエス
テル樹脂、ポリウレタン樹脂等の熱硬化性樹脂を挙げる
ことができ、表装材の樹脂と目的に合わせて適宜選択す
ることが可能である。The resin used for the backing material of the present invention has good adhesiveness to the surface material and has a performance required by the finally obtained composite molded article, that is, a molded article made of a single material and thick by composite molding. When making, for example, economy, weight,
There is no particular limitation as long as it has the ability to improve the defects such as strength, for example, acrylic resin, vinyl chloride resin,
A thermoplastic resin such as polypropylene resin, a thermosetting resin such as an unsaturated polyester resin or a polyurethane resin can be mentioned, and it can be appropriately selected according to the resin of the covering material and the purpose.

【００２２】本発明は裏打ち材の使用により、例えば強
度、重量、経済性等に関する表装材の欠点等を補うこと
を目的とするものであるから、裏打ち材の樹脂は、表装
材と異なる種類の樹脂、または表装材と同じ種類であっ
ても配合や添加剤が異なるもの等、表装材とは異なる組
成の樹脂が用いられる。Since the purpose of the present invention is to make up for defects such as strength, weight, economy, etc. of the covering material by using the lining material, the resin of the lining material is different from that of the covering material. A resin or a resin having a composition different from that of the surface covering material, such as a resin having the same type as the surface covering material but different composition or additives, is used.

【００２３】また裏打ち材には、各種フィラーや各種添
加剤等を配合することも可能であり、これにより、例え
ば表装材と熱膨脹率を近似させて複合成形体の熱的耐久
性を向上させたり、裏打ち材の伝熱性を改良して複合成
形体全体の熱拡散性を向上させて耐熱性を改良する等、
各種の機能を付与することも可能である。It is also possible to mix various fillers, various additives, etc. in the lining material, whereby the thermal expansion coefficient of the composite molding is improved by approximating the thermal expansion coefficient to that of the surface material, for example. , Improving the heat conductivity of the backing material to improve the thermal diffusivity of the entire composite molded body to improve the heat resistance, etc.
It is also possible to add various functions.

【００２４】さらにまた裏打ち材の樹脂と表装材との接
着力が不足する場合、表装材の裏面に、プライマーを塗
布する等して接着性を改良することも可能である。Furthermore, when the adhesive force between the resin of the lining material and the surface material is insufficient, it is possible to improve the adhesiveness by applying a primer to the back surface of the surface material.

【００２５】例えば裏打ち材に本発明の好ましい態様の
１つであるポリウレタン樹脂を使用する発泡成形の場合
には、該樹脂により表装材の強度補強が可能になるばか
りでなく、多種用途により要求される強度を損なわない
範囲でポリウレタン樹脂の発泡倍率を変えることにより
軽量化することも可能であるし、断熱性能を持たせるこ
とも可能である。For example, in the case of foam molding in which a polyurethane resin, which is one of the preferred embodiments of the present invention, is used as the backing material, the resin not only enables the strength of the covering material to be reinforced, but is required for various purposes. It is possible to reduce the weight by changing the foaming ratio of the polyurethane resin within the range that does not impair the strength, and it is also possible to provide heat insulation performance.

【００２６】本発明の複合成形体に種々の方法で作るこ
とができるが、例えば表装材の裏面（製品面と反対側の
成形面）に、接着剤を介することなしに、前記のように
表装材とは異なる組成の樹脂組成物を配し、該組成物を
硬化せしめて裏打ち材を形成させるととも、表装材と裏
打ち材とを接着一体化させることにより本発明の複合成
形体を製造することができる。これを具体的に実現する
方法には種々あるが、例えば（ｉ）表装材と他の型材と
で成形用型を構成させ、該型内に重合性の樹脂組成物を
注入又は投入し、重合・硬化させて裏打ち材を成形する
と同時に表装材と接着一体化する方法、（ii）成形用型
の片面に表装材を配した後、該表装材の裏面に重合性の
樹脂組成物を注入又は投入し、重合・硬化させて裏打ち
材を成形すると同時に表装材と接着一体化する方法、
（iii)成形用型の片面に表装材を配した後、該表装材の
裏面に溶融した熱可塑性樹脂を配し冷却・硬化させて裏
打ち材を成形すると同時に表装材と接着一体化する方法
等を挙げることができる。これらの方法では、通常の注
型重合法、射出成形法、圧縮成形法、ＲＩＭ成形法等で
採用される成形条件の下で行うことができる。The composite molded article of the present invention can be manufactured by various methods. For example, the back surface of the facing material (the molding surface opposite to the product surface) can be coated as described above without an adhesive. A resin composition having a composition different from that of the material is arranged, and the composition is cured to form a backing material, and at the same time, the composite molding of the present invention is manufactured by adhesively integrating the facing material and the backing material. be able to. There are various methods for specifically realizing this. For example, (i) a molding die is composed of a surface material and another mold material, and a polymerizable resin composition is injected or charged into the mold to perform polymerization. A method of curing and forming a backing material and at the same time adhering and integrating with a surface material, (ii) placing a surface material on one side of a molding die, and then injecting a polymerizable resin composition into the back surface of the surface material or A method of charging, polymerizing and curing to form a lining material, and at the same time, adhesively integrating with a surface material,
(Iii) A method of arranging a cover material on one surface of a molding die, arranging a molten thermoplastic resin on the back surface of the cover material, and cooling and curing it to form a lining material and at the same time, to bond and integrate the cover material. Can be mentioned. These methods can be carried out under molding conditions adopted in usual casting polymerization method, injection molding method, compression molding method, RIM molding method and the like.

【００２７】また裏打ち材の成形に際して、最終的に得
られる複合成形体を使用場所などに取付ける為の治具や
補強用リブ等の付属物をインサート成形することも可能
であるし、裏打ち材側の表装材とは反対側の面に補強用
のリブ構造とか、取付けに便利な構造等を付与した成形
体を作ることも可能であり、複合成形体の使用に際して
の利便性を向上することが可能である。When molding the backing material, it is also possible to insert-mold an accessory such as a jig or a reinforcing rib for attaching the finally obtained composite molded body to the place of use. It is also possible to make a molded product with a reinforcing rib structure or a structure convenient for mounting on the surface opposite to the surface covering material, and it is possible to improve the convenience when using the composite molded product. It is possible.

【００２８】本発明の裏打ち材の成形に好ましい態様の
１つとして、ポリウレタンの発泡成形を挙げることが出
来る。この場合、例えば表装材と他の型材とで構成され
る成形用型の空間部に、各種ポリオール、ポリイソシア
ネート、発泡剤、硬化剤、その他添加剤等よりなる反応
液を通常用いられる種々の方法で注入し、重合・硬化さ
せることにより、裏打ち材の成形と同時に表装材と裏打
ち材とを接着一体化させた複合成形体を得ることが出来
る。As one of the preferred embodiments for molding the backing material of the present invention, polyurethane foam molding can be mentioned. In this case, for example, various methods which are usually used with a reaction liquid containing various polyols, polyisocyanates, a foaming agent, a curing agent, and other additives in the space of a molding die composed of a surface material and other mold materials. By injecting, and polymerizing and curing, it is possible to obtain a composite molded body in which the facing material and the backing material are bonded and integrated simultaneously with the molding of the backing material.

【００２９】前記の注入に当っては、成形用型を開いた
状態で注入することも可能であるし、密閉した状態で注
入することも可能であり、通常ポリウレタンの成形に用
いる低圧注入機、高圧注入機等を適宜使用することが可
能である。密閉した成形用型等に高圧注入機（高圧発泡
機という場合もある）を用いて射出注入して成形する場
合は、一般にＲＩＭ成形と呼ばれる成形性とほぼ同じ概
念となる。In the above-mentioned injection, it is possible to inject in a state where the molding die is open or in a closed state, and a low-pressure injection machine usually used for molding polyurethane, A high-pressure injection machine or the like can be used as appropriate. When injection molding is performed using a high-pressure injection machine (sometimes referred to as a high-pressure foaming machine) in a closed molding die or the like, the concept is generally the same as the moldability called RIM molding.

【００３０】またポリウレタンの発泡成形の１つとして
知られているスプレー発泡法の使用も可能であるが、該
発泡法は表装材の裏面に一定の厚みで平滑な表面を有す
る裏打ち材を形成させる必要がある場合には必ずしも好
ましい方法とはならない。It is also possible to use a spray foaming method known as one of foam molding of polyurethane, which foaming method forms a backing material having a constant thickness and a smooth surface on the back surface of the facing material. It is not always the preferred method if necessary.

【００３１】ポリウレタンの場合、反応液の組成や発泡
倍率等を変えることにより、硬度、強度、密度等の諸物
性を変えることが出来るとともに、重合硬化に際しての
発熱量が過度に高くならない為、高温下にさらすことが
適当でない表装材の裏打ち成形には特に有利である。In the case of polyurethane, the physical properties such as hardness, strength and density can be changed by changing the composition of the reaction solution, the expansion ratio, etc., and the calorific value during polymerization and curing does not become excessively high. It is particularly advantageous for backing molding of facing materials where underexposure is not appropriate.

【００３２】また本発明の複合成形体は、一旦裏打ち材
を成形した後、該裏打ち材の表面に例えば前記樹脂組成
物（コンパウンド）を配し、該組成物を硬化せしめて表
装材を形成せしめるとともに、表装材と裏打ち材とを接
着一体化させることによっても製造することができる。In the composite molded article of the present invention, after the backing material is once molded, the resin composition (compound) is placed on the surface of the backing material, and the composition is cured to form the covering material. At the same time, it can be manufactured by adhering and integrating the facing material and the backing material.

【００３３】以上のようにして、本発明においては表装
材と裏打ち材とが隙間なく接着一体化した複合成形体を
簡便容易に製造することができるので複雑な形状を有す
る表装材にも適用可能であり形状の自由度を広げること
ができる。As described above, according to the present invention, a composite molded body in which the surface material and the backing material are adhered and integrated without a gap can be simply and easily manufactured, so that the invention can be applied to the surface material having a complicated shape. Therefore, the degree of freedom in shape can be expanded.

【００３４】また、本発明の天然石調複合成形体は、表
装材と裏打ち材が隙間なく接着一体化しているので、隙
間が原因となって発生する表装材の耐衝撃性低下を回避
することができるとともに、例えば加熱と冷却が繰り返
されるような過酷な環境下でも接着面の耐久性は優れた
ものとなる。Further, in the natural stone-like composite molded article of the present invention, since the surface material and the backing material are adhered and integrated without a gap, it is possible to avoid a decrease in impact resistance of the surface material caused by the gap. In addition, the durability of the adhesive surface becomes excellent even in a severe environment where heating and cooling are repeated.

【００３５】このように本発明の天然石調複合成形体
は、優れた特性を有するとともに簡便容易に製造するこ
とが可能であるので、壁材、床材、天井材等の建材・内
装材分野、カウンター、洗面化粧台天板等の住設機器分
野、テーブルトップ、家具表面材等の調度品分野等で有
利に使用することが可能であり有用である。As described above, since the natural stone-like composite molded article of the present invention has excellent characteristics and can be easily and easily manufactured, it can be used in the field of building materials / interior materials such as wall materials, floor materials, and ceiling materials. It is useful and useful in the field of home appliances such as counters and vanity top plates, and in the field of furniture such as table tops and furniture surface materials.

【００３６】[0036]

【実施例】以下実施例を挙げて本発明をさらに具体的に
説明するが、これに制限されるものではない。 実施例１ 長さ４００ｍｍ、巾３００ｍｍ、厚み２ｍｍのメタクリ
ル樹脂と水酸化アルミニウムを主成分とするアクリル系
人工大理石板（株式会社クラレ製 エルドール）を１４
０℃に加熱した後、木型にはさみ込み、加圧賦形して、
図１に示す如く、Ｒ曲げ部が内径１８ｍｍ、外径２０ｍ
ｍｍの前垂部を有し、該前垂部が長さ４００ｍｍ、高さ
２０ｍｍの形状を有する表装材を得た。The present invention will be described in more detail with reference to the following examples, but the invention is not limited thereto. Example 1 An acrylic artificial marble board (Kuraray Co., Ltd. Eldor) having a length of 400 mm, a width of 300 mm and a thickness of 2 mm and containing methacrylic resin and aluminum hydroxide as main components was used.
After heating to 0 ° C, insert it into a wooden mold and press
As shown in Fig. 1, the R bend has an inner diameter of 18 mm and an outer diameter of 20 m.
A front mounting material having a front hanging portion of mm, the front hanging portion having a shape of 400 mm in length and 20 mm in height was obtained.

【００３７】表装材を図２に示すように金型にセット
し、空間部に分子量５００〜６００のポリエーテル系ポ
リオール、分子量３００〜４００のポリメチレンポリフ
ェニルポリイソシアネート、発泡剤（水）、硬化剤（ト
リエタノールアミン）を主成分とする混合液を注入し、
型温４０℃、１０ｋｇ／ｃｍ² の加圧下で２５分間放置
した後、型より成形品を取り出し、発泡ポリウレタン部
が密度０．５６ｇ／ｃｍ³ の硬度ポリウレタンである図
３の複合成形体を得た。表装材と、裏打ち材である発泡
ポリウレタンとは隙間なく接着しており、複合成形体の
平面部および曲がり部に２８ｇの鋼球を９０ｃｍの高さ
より落下させても割れは発生しなかった。As shown in FIG. 2, the covering material is set in a mold, and a polyether polyol having a molecular weight of 500 to 600, a polymethylene polyphenyl polyisocyanate having a molecular weight of 300 to 400, a foaming agent (water), and a curing agent are set in the space. Inject a mixture containing the agent (triethanolamine) as the main component,
After standing for 25 minutes under a mold temperature of 40 ° C. and a pressure of 10 kg / cm ² , the molded product was taken out from the mold to obtain a composite molded product of FIG. 3 in which the polyurethane foam part was a hardness polyurethane having a density of 0.56 g / cm ³ . It was The surface covering material and the foamed polyurethane as the backing material were adhered to each other without any gap, and no cracks occurred even when a 28 g steel ball was dropped from a height of 90 cm to the flat surface portion and the curved portion of the composite molded body.

【００３８】実施例２ 重合度１５００のポリメチルメタクリレート２０％を溶
解したメチルメタクリレートシラップ８０重量部、ネオ
ペンチルグリコールジメタクリレート２０重量部、１，
４（８）−Ｐ−メンタジエン０．０１重量部、２，２′
−アゾビス（４−メトキシ−２，４−ジメチルパレロニ
トリル）０．００３重量部及び２，２′ビス（ｔ−ブチ
ルパーオキシ）ブタン０．１重量部、ジ−ｔ−ブチルパ
ーオキサイド０．３重量部、ジーｔ−ブチルパーオキシ
ヘキサヒドロテレフタレート０．０５重量部を混合溶解
し、２枚のガラス板及びガスケットで１０ｍｍ間隔にな
るように組立てられたセルに注入し、６０℃で１時間重
合して部分架橋ゲル状重合体を得た。Example 2 80 parts by weight of methyl methacrylate syrup in which 20% of polymethyl methacrylate having a degree of polymerization of 1500 was dissolved, 20 parts by weight of neopentyl glycol dimethacrylate, 1,
0.01 parts by weight of 4 (8) -P-menthadiene, 2,2 '
-Azobis (4-methoxy-2,4-dimethylpaleronitrile) 0.003 parts by weight and 2,2'bis (t-butylperoxy) butane 0.1 parts by weight, di-t-butylperoxide 0. 3 parts by weight and 0.05 parts by weight of di-t-butylperoxyhexahydroterephthalate were mixed and dissolved, and the mixture was poured into a cell assembled with two glass plates and a gasket at 10 mm intervals, and the mixture was heated at 60 ° C. for 1 hour. Polymerization gave a partially crosslinked gel polymer.

【００３９】部分架橋ゲル状重合体４０重量％と水酸化
アルミニウム６０重量％を混練して得られたコンパウン
ドを予め１３５℃に加熱した金型内に投入し、１００ｋ
ｇ／ｃｍ² で２０分間保圧した後、金型を１００℃まで
冷却してから成形品を取り出し、図１の形状を有する成
形品を得た。A compound obtained by kneading 40% by weight of the partially crosslinked gel polymer and 60% by weight of aluminum hydroxide was put into a mold preheated to 135 ° C., and 100 k
After holding the pressure at g / cm ² for 20 minutes, the mold was cooled to 100 ° C., and the molded product was taken out to obtain a molded product having the shape shown in FIG.

【００４０】前記成形品を表装材とすることを除き、実
施例１と同様の方法で成形し図３の複合成形体を得た。
表装材と、裏打ち材である発泡ポリウレタンとは隙間な
く接着しており、複合成形体の外観は良好であった。Molding was carried out in the same manner as in Example 1 except that the above-mentioned molded product was used as a cover material to obtain a composite molded product shown in FIG.
The exterior material and the polyurethane foam as the backing material were adhered to each other without any gap, and the appearance of the composite molded article was good.

【００４１】実施例３ 長さ２５０ｍｍ、巾２００ｍｍ、厚み３ｍｍの実施例１
と同様のアクリル系人工大理石板を型温４０℃の長さ２
５５ｍｍ、巾２０５ｍｍの平板金型内にセットし、該人
工大理石板の裏面に、２００℃の溶融した分子量１５０
０のポリメチルメタクリレート約６２８ｇを載せた後、
金型を閉じ、１００ｋｇ／ｃｍ² で１０分間保圧してプ
レス成形を行い複合成形体を得た。得られた複合成形体
の人工大理石と裏打ち材は隙間なく接着し、外観は良好
であった。Example 3 Example 1 having a length of 250 mm, a width of 200 mm and a thickness of 3 mm
Acrylic artificial marble plate similar to the one with a mold temperature of 40 ℃ length 2
It is set in a flat plate mold having a width of 55 mm and a width of 205 mm, and the melted molecular weight of 150 at 200 ° C. is set on the back surface of the artificial marble plate.
After placing about 628 g of polymethylmethacrylate of 0,
The mold was closed, and press-molding was performed under a pressure of 100 kg / cm ² for 10 minutes to obtain a composite molded body. The artificial marble of the obtained composite molded article and the backing material adhered to each other without any gap, and the appearance was good.

【００４２】実施例４ 長さ２５０ｍｍ、巾２００ｍｍ、厚み１０ｍｍのメタク
リル樹脂板を型温１３０℃、長さ２５５ｍｍ、巾２０５
ｍｍの平金型にセットし、該メタクリル樹脂板の表面
に、実施例２と同じコンパウンド２６５ｇを投入し、１
００ｋｇ／ｃｍ²で２０分間保圧した後、金型を１００
℃まで冷却してから成形品を取り出した。得られた複合
複合成形体は、メタクリル樹脂板を裏打ち材とし、天然
石調の外観を有する厚さ約３ｍｍの表装材より構成さ
れ、外観は良好であった。Example 4 A methacrylic resin plate having a length of 250 mm, a width of 200 mm and a thickness of 10 mm was molded at a mold temperature of 130 ° C., a length of 255 mm and a width of 205.
mm flat mold and charged with 265 g of the same compound as in Example 2 on the surface of the methacrylic resin plate.
After holding the pressure at 00 kg / cm ² for 20 minutes, set the mold to 100
The molded product was taken out after cooling to ℃. The obtained composite composite molded article was composed of a covering material having a thickness of about 3 mm and having a natural stone-like appearance with a methacrylic resin plate as a lining material, and the appearance was good.

【００４３】比較例１ 厚さ１８ｍｍの合板を使用して図４の形状を有する基板
（長さ４００ｍｍ、底辺２９０ｍｍ、高さ１８ｍｍ、Ｒ
曲げ部半径１８ｍｍ）を作成した。この基板上に実施例
１を表装材を両者の曲がり部を一致させるようにしてゴ
ム系接着剤で接着して、複合成形品を得た。Comparative Example 1 A substrate having the shape shown in FIG. 4 was manufactured using a plywood plate having a thickness of 18 mm (length 400 mm, bottom 290 mm, height 18 mm, R
The bending portion radius was 18 mm). A composite molded article was obtained by adhering the surface covering material of Example 1 on this substrate with a rubber-based adhesive so that the curved portions of both were aligned.

【００４４】複合成形品の曲がり部に、表装材と基板と
の隙間が観察され、２８ｇの鋼球を９０ｃｍの高さより
曲がり部に落下させると、割れの発生する箇所があっ
た。A gap between the cover material and the substrate was observed in the curved portion of the composite molded product, and when a 28 g steel ball was dropped into the curved portion from a height of 90 cm, there was a portion where cracking occurred.

【００４５】[0045]

【発明の効果】以上述べたように本発明は、有機及び／
又は無機フィラーを含む樹脂成形品よりなる表装材の裏
面に、接着剤を介することなしに、表装材とは異なる組
成の樹脂よりなる裏打ち材を接着一体化している複合成
形体であるから、複雑な形状を有する複合成形体であっ
ても表装材と裏打ち材とは隙間なく接着一体化している
ので、隙間に起因する衝撃強度の低下等もなく、また過
酷な環境下で使用しても耐久性は良好である。As described above, the present invention is
Or, since it is a composite molded body in which a backing material made of a resin molded article containing an inorganic filler is bonded and integrated with a backing material made of a resin having a composition different from that of the surface mounting material without an adhesive, it is complicated. Even if it is a composite molded product with a unique shape, the exterior material and the backing material are bonded and integrated without a gap, so there is no decrease in impact strength due to the gap, and it is durable even when used in a harsh environment. The sex is good.

【００４６】必要な強度を確保したり、厚みからくる重
厚感を確保する等の為、厚い成形品を要求されることも
多いが、このような場合本発明の複合成形体では、薄い
表装材で所望の意匠性や機能等を発現し、例えば表装材
材料が高価な場合には安価な材料で裏打ち材を形成して
コストダウンを計ったり、表装材材料の比重が高い場合
には低比重の材料で裏打ち材を形成して軽量化を計った
り、表装材の材料を薄くすると強度が不足する場合には
裏打ち材で強度補強を計ったり、また前記のような各種
の目的を幾つか同時に発現させることを計る等、表装材
の材質や最終的に得られる複合成形体の用途や、複合化
の目的に応じて適宜裏打ち材を選定することにより表装
材材料の欠点を補い種々の要望を満たす複合成形体を得
ることができるし、表装材と裏打ち材の組合わせにより
種々の機能を付与することもできる。A thick molded product is often required in order to secure the required strength and a solid feeling due to the thickness. In such a case, in the composite molded product of the present invention, a thin cover material is used. In order to achieve the desired design characteristics and functions, for example, when the surface covering material is expensive, a backing material is formed with an inexpensive material to reduce the cost, or when the surface covering material has a high specific gravity, a low specific gravity is used. If you want to reduce the weight by forming a lining material with the material of the above, or if the material of the surface covering material is thin and the strength is insufficient, measure the strength reinforcement with the lining material, and also do some of the above various purposes at the same time. To meet the various demands to compensate for the defects of the covering material by appropriately selecting the backing material according to the material of the covering material, the intended use of the composite molded body to be finally obtained, and the purpose of compounding It is possible to obtain a filled composite molding It is also possible to impart various functions by a combination of face material and the backing material.

【００４７】また本発明は、有機フィラー及び／又は無
機フィラーを含む薄い樹脂成形品よりなる表装材の裏面
に、接着剤を介することなしに、表装材とは異なる組成
の樹脂組成物を配し、該組成物を硬化せしめ裏打ち材を
成形するとともに、表装材と接着一体化させることを特
徴とする複合成形体の製造方法、及び表装材とは異なる
組成の裏打ち材の表面に、表装材を形成する有機フィラ
ー及び／又は無機フィラーを含有する樹脂組成物を配
し、該組成物を硬化せしめて表装材を形成せしめるとと
もに、表装材と裏打ち材とを接着一体化させることを特
徴とする複合成形体の製造方法であるから、複雑な形状
であっても表装材と裏打ち材との間に隙間を生ずること
なく、前述のような高品質の複合成形体を簡便容易に製
造することができ、形状の自由度も大きい。Further, according to the present invention, a resin composition having a composition different from that of the covering material is arranged on the back surface of the covering material made of a thin resin molded product containing an organic filler and / or an inorganic filler without an adhesive. , A method of manufacturing a composite molded article characterized by curing the composition to form a backing material, and adhering and integrating the backing material, and a surface material on the surface of the backing material having a composition different from that of the surface material. A composite characterized in that a resin composition containing an organic filler and / or an inorganic filler to be formed is arranged, and the composition is cured to form a cover material, and the cover material and the backing material are bonded and integrated. Since it is a method for manufacturing a molded body, it is possible to easily and easily manufacture a high-quality composite molded body as described above without causing a gap between the facing material and the lining material even if the shape is complicated. , Jo degree of freedom is also large.

【００４８】以上のように、本発明によれば一種の材料
で成形した場合に発生する種々の欠点を補う、意匠性、
耐久性、形状の自由度に富んだ複合成形体が提供され、
しかも簡便容易に製造することが可能であり産業上有用
である。As described above, according to the present invention, the designability, which compensates for various drawbacks which occur when molded with one kind of material,
A composite molded body with high durability and flexibility in shape is provided,
Moreover, it can be easily and easily manufactured and is industrially useful.

【図面の簡単な説明】[Brief description of the drawings]

【図１】本発明に用いる表装材の一例を示す斜視図であ
る。FIG. 1 is a perspective view showing an example of a cover material used in the present invention.

【図２】本発明に用いる金型に表装材をセットした状態
の一例を示す断面図である。FIG. 2 is a cross-sectional view showing an example of a state in which a cover material is set in a mold used in the present invention.

【図３】本発明の天然石調複合成形体の一例を示す斜視
図である。FIG. 3 is a perspective view showing an example of a natural stone-like composite molded article of the present invention.

【図４】従来の表装材接着用基板の一例を示す斜視図で
ある。FIG. 4 is a perspective view showing an example of a conventional substrate for adhering material.

【符号の説明】[Explanation of symbols]

１ 上型 ２ 下型 ３ 表装材 ４ 空間部 1 Upper mold 2 Lower mold 3 Surface material 4 Space

Claims (3)

【特許請求の範囲】[Claims] 【請求項１】 有機フィラー及び／又は無機フィラーを
含有する樹脂成形品よりなる表装材の裏面に、表装材と
は異なる組成の樹脂よりなる裏打ち材を接着一体化して
いることを特徴とする天然石調複合成形体。1. A natural stone characterized in that a backing material made of a resin having a composition different from that of the surface mounting material is bonded and integrated to the back surface of the surface mounting material made of a resin molded product containing an organic filler and / or an inorganic filler. Tone composite molded body. 【請求項２】 有機フィラー及び／又は無機フィラーを
含有する樹脂成形品よりなる表装材の裏面に、表装材と
は異なる組成の樹脂組成物を配し、該組成物を硬化せし
めて裏打ち材を形成せしめるとともに、表装材と裏打ち
材とを接着一体化させることを特徴とする天然石調複合
成形体の製造方法。2. A backing material comprising a resin composition having a composition different from that of the surface material, which is provided on the back surface of the surface material made of a resin molded product containing an organic filler and / or an inorganic filler, and the composition is cured to form a backing material. A method for producing a natural stone-like composite molded article, which comprises forming and forming an adhesive material and a backing material. 【請求項３】 表装材とは異なる組成の裏打ち材の表面
に、表装材を形成する有機フィラー及び／又は無機フィ
ラーを含有する樹脂組成物を配し、該組成物を硬化せし
めて表装材を形成せしめるとともに、表装材と裏打ち材
とを接着一体化させることを特徴とする複合成形体の製
造方法。3. A resin composition containing an organic filler and / or an inorganic filler forming a surface covering material is arranged on the surface of a backing material having a composition different from that of the surface covering material, and the composition is cured to form the surface covering material. A method for producing a composite molded body, which comprises forming and forming a fronting material and a backing material by adhesion.