Thermosetting resin molding

Abstract

To provide a thermosetting resin molding which enables a housing with a magnet and a cleaning tool with a magnet to be used even in artificial marble.SOLUTION: A thermosetting resin molding 1 has at least a gel coat layer 3 and a resin layer 5. A magnet body layer 4 is provided between the gel coat layer 3 and the resin layer 5. The magnet body layer 4 is blended with a matrix resin composed of a thermosetting resin, a curing agent containing an organic peroxide as a main component, and 50 pts.wt. or more of ferromagnetic powder or particle with respect to 100 pts.wt. of the matrix resin.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to a thermosetting resin molded article having at least a gel coat layer and a resin layer, and in particular to a thermosetting resin molded article that can be suitably used for washbasins and the like. [Background technology]

[0002] Thermosetting resin molded bodies are generally called artificial marble or synthetic marble, and because they are strong, water-resistant, and highly aesthetically pleasing, they are widely used in residential facilities such as bathtubs, kitchen counters, and wash basins (see, for example, Patent Document 1).

[0003] Meanwhile, for cleaning tools and storage accessories for home appliances, magnetic products have been put on the market, and a so-called aerial storage has been proposed, where items are held to the steel wall of the bathroom by magnets (see, for example, Patent Document 2, etc.). This aerial storage not only makes effective use of space, but also makes wiping and cleaning easier because items are not placed directly on the surface, and has been shared on social media networks and has become a hot topic. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] JP 2010-24308 A [Patent Document 2] JP 2023-35721 A Summary of the Invention [Problem to be solved by the invention]

[0005] When using aerial storage on artificial marble or other surfaces where magnets do not stick, products using suction cups or film hooks are used instead of magnets. However, there are complaints that the suction power is weak and the items fall off easily. In addition, suction cups made of polyvinyl chloride are plastic, which causes problems such as dissolving polystyrene.

[0006] In view of the above-mentioned circumstances, an object of the present invention is to provide a thermosetting resin molded article that enables the use of magnetic storage devices and magnetic cleaning tools even on artificial marble and the like. [Means for solving the problem]

[0007] A first thermosetting resin molded article of the present invention that achieves the above object is a thermosetting resin molded article having at least a gel coat layer and a resin layer, a magnetic layer is provided between the gel coat layer and the resin layer, The magnetic layer is a matrix resin made of a thermosetting resin; A curing agent mainly composed of an organic peroxide; The composition is characterized in that 50 parts by weight or more of ferromagnetic powder or granules are blended with 100 parts by weight of the matrix resin.

[0008] A second thermosetting resin molded article of the present invention that achieves the above object is a thermosetting resin molded article having at least a gel coat layer and a resin layer, The resin layer is a matrix resin made of a thermosetting resin; A curing agent mainly composed of an organic peroxide; The composition is characterized in that 50 parts by weight or more of ferromagnetic powder or granules are blended with 100 parts by weight of the matrix resin. Effect of the Invention

[0009] According to the first thermosetting resin molded body of the present invention and the second thermosetting resin molded body of the present invention, it is possible to use magnetic storage and magnetic cleaning tools. In particular, in a so-called high-back washbasin made of artificial marble in which a counter and a back guard that rises upward from the rear of the counter are integrally formed, it is possible to store magnetic storage and magnetic cleaning tools in the air by holding them on the back guard. [Brief description of the drawings]

[0010] [Figure 1] FIG. 2 is a diagram illustrating a cross section of a first thermosetting resin molded body. [Diagram 2] FIG. 4 is a diagram illustrating a cross section of a second thermosetting resin molded body. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0011] The first thermosetting resin molded body and the second thermosetting resin molded body of the present invention can be used, for example, for washbasins, bathtubs, kitchen counters, etc., and are suitable for casting of thick-walled products of 5 mm or more, which are considered difficult to produce by injection molding. Although press molding is also possible, this is not preferable because there is a risk that the mold will be worn down by the ferromagnetic powder or particles such as iron powder that are blended when pressure is applied. Hereinafter, the first thermosetting resin molded body will be referred to as the first molded body, and the second thermosetting resin molded body will be referred to as the second molded body, and an embodiment of the present invention will be described with reference to the drawings.

[0012] First, the first molded body will be described. Fig. 1 is a schematic diagram showing a cross section of a first molded body 1.

[0013] 1, the first molded body 1 in this embodiment includes, in order from the surface side (the upper side in the figure), a gel coat layer (top gel coat layer) 3, a magnetic layer 4, a resin layer 5, and a concealing gel coat layer 6. That is, the first molded body 1 includes the magnetic layer 4 between the gel coat layer 3 and the resin layer 5.

[0014] The gel coat layer 3 and the concealing gel coat layer 6 are layers having a thickness of about 0.3 mm, each of which is made of a matrix resin such as unsaturated polyester, a hardener, and styrene as a solvent. The gel coat layer 3 and the concealing gel coat layer 6 are transparent, semi-transparent, or opaque layers.

[0015] The magnetic layer 4 is a layer with a thickness of about 0.3 mm, similar to the gel coat layer 3, and is made by compounding ferromagnetic powder or particles, a curing agent mainly composed of organic peroxide, and styrene as a solvent into a matrix resin. As the matrix resin, unsaturated polyester resin, epoxy resin, phenol resin, melamine resin, carbon resin, mixtures of these resins with acrylic syrup, or mixtures of these resins can be used.

[0016] As the ferromagnetic powder or granules, iron powder or ferrite powder is preferable, taking into consideration the high reactivity of the curing agent, which is mainly composed of organic peroxide. In addition, in order to exert sufficient holding power for magnetic storage and magnetic cleaning tools, it is necessary to mix 50 parts by weight or more with respect to 100 parts by weight of matrix resin. Note that the more the mixing ratio of the ferromagnetic powder or granules is increased, the stronger the magnetism becomes when a magnetic field is applied from the outside, but the amount of matrix resin (resin component) decreases accordingly, and the mechanical strength, etc. decreases. For this reason, it is preferable that the amount of the ferromagnetic powder or granules is 200 parts by weight or less with respect to 100 parts by weight of matrix resin.

[0017] The curing agent is not particularly limited as long as it is mainly composed of an organic peroxide. Examples of the organic peroxide include methyl ethyl ketone peroxide, di(4-tert-butylcyclohexyl)peroxydicarbonate, benzoyl peroxide, lauroyl peroxide, stearoyl peroxide, bis(4-t-butylcyclohexyl)peroxydicarbonate, t-hexylperoxy-2-ethylhexanoate, t-butylperoxy-2-methylcyclohexane, t-aluminum peroxybenzoate, and dicumyl peroxide. Specifically, products with the name "Permec N" (manufactured by NOF Corp.) containing methyl ethyl ketone peroxide as the main component, and products with the name "Percadox 16" (manufactured by Nouryon Chemical Co., Ltd.) containing di(4-tert-butylcyclohexyl)peroxydicarbonate as the main component can be suitably used. The curing agent is mixed in an amount of less than 1 part by weight per 100 parts by weight of the matrix resin.

[0018] The resin layer 5 is, for example, a layer of about 7 to 9 mm, and is a mixture of a matrix resin such as an unsaturated polyester resin, a filler such as glass powder, calcium carbonate, aluminum hydroxide, and additives such as a curing agent, a curing accelerator, an ultraviolet absorber, a decorative material such as crushed natural stone or resin powder, and an antifoaming agent. A small amount (for example, less than 50 parts by weight per 100 parts by weight of the matrix resin) of ferromagnetic powder or particles may also be mixed into the resin layer 5.

[0019] Next, the second molded body will be described. Fig. 2 is a schematic diagram showing a cross section of the second molded body 2.

[0020] 1, the second molded body 2 in this embodiment includes, in order from the surface side (the upper side in the figure), a gel coat layer (top gel coat layer) 3, a second resin layer 7, and a concealing gel coat layer 6. Compared to the first molded body 1 described above, the second molded body 2 has the same gel coat layer 3 and concealing gel coat layer 6, but the magnetic layer 4 is omitted and the composition of the second resin layer 7 is different from that of the resin layer 5.

[0021] The second resin layer 7 is also a layer of, for example, about 7 to 9 mm, similar to the resin layer 5, and is a compound of the resin layer 5 with iron powder or ferrite powder (ferromagnetic powder or granules). The ferromagnetic powder or granules are mixed in an amount of 50 parts by weight or more per 100 parts by weight of the matrix resin so as to exert sufficient holding power for magnetic storage and magnetic cleaning tools. In addition, in order to avoid a decrease in mechanical strength, it is preferable to mix 200 parts by weight or less per 100 parts by weight of the matrix resin. The curing agent is, like the curing agent of the magnetic layer 4, a material mainly composed of organic peroxide, for example, a product named "Permec N" (manufactured by NOF Corporation), mixed in an amount of less than 1 part by weight per 100 parts by weight of the matrix resin.

[0022] Next, an example of a method for producing the first molded body 1 and the second molded body 2 by cast molding will be specifically described, but the first molded body 1 and the second molded body 2 of the present invention are not limited to the manufacturing method described below.

[0023] In the first molded body 1, a compound for magnetic layer constituting the magnetic layer 4 and a compound for resin layer constituting the resin layer 5 are prepared. The compound for magnetic layer is prepared by kneading the composition shown in Table 1 below. It is advisable to add iron powder in small amounts at the end.

[0024] [Table 1] Then, gel coat resin is sprayed onto the surface of the lower mold to a thickness of about 0.3 mm, and this is cured at a temperature of about 60° C. to form the gel coat layer 3. After the gel coat layer 3 is formed, a compound for the magnetic layer is sprayed onto the surface to a thickness of about 0.3 mm and cured to form the magnetic layer 4. Note that the compound for the magnetic layer may be sprayed onto the surface without curing the sprayed gel coat resin, and then cured at a temperature of about 60° C. to form the gel coat layer 3 and the magnetic layer 4 simultaneously.

[0025] In this state, the upper mold coated with the gel coat resin that forms the concealing gel coat layer 6 is set, and the compound for the resin layer is injected into the cavity formed by both molds. Then, it is cured at a predetermined temperature, the upper mold is separated from the lower mold, and the molded body is taken out from the lower mold and demolded. After that, this molded body is secondary cured in a curing furnace at 80°C to 90°C to complete the reaction, thereby producing a first molded body 1 with a thickness of about 10 mm.

[0026] For the second molded body 2, first, the composition having the composition shown in Table 2 below is kneaded to prepare a compound for the second resin layer that constitutes the second resin layer .

[0027] [Table 2] Next, the gel coat resin is sprayed onto the surface of the lower mold to a thickness of about 0.3 mm, and then cured at a temperature of about 60°C to form the gel coat layer 3. After the gel coat layer 3 is formed, the upper mold coated with the gel coat resin that forms the concealing gel coat layer 6 is set, and the compound for the second resin layer is injected into the cavity formed by both molds. Then, the mixture is cured at a predetermined temperature, the upper mold is separated from the lower mold, and the molded body is taken out of the lower mold and demolded. After that, the molded body is secondary cured in a curing furnace at 80°C to 90°C to complete the reaction, thereby producing a second molded body 2 with a thickness of about 10 mm.

[0028] By using the above-mentioned manufacturing method, a high-back washbasin made of the first molded body 1 and a high-back washbasin made of the second molded body 2 were manufactured, and it was confirmed that the back guard exhibited sufficient holding power for the use of magnetic storage and magnetic cleaning tools. Compared to the second molded body 2, the first molded body 1 may have slightly inferior holding power for magnetic storage, etc., but the amount of ferromagnetic powder or granules such as iron powder can be reduced, making it superior in terms of cost.

[0029] Furthermore, when the iron powder in the compound for the magnetic layer shown in Table 1 for the first molded body 1, and the iron powder in the compound for the second resin layer shown in Table 2 for the second molded body 2, were mixed in an amount of less than 50 parts by weight per 100 parts by weight of matrix resin, it was found that sufficient holding power for magnetic storage, etc. could not be obtained and the products were not viable as products.

[0030] On the other hand, when more than 200 parts by weight of iron powder in the compound for the magnetic layer shown in Table 1 was used for the first molded body 1, and when more than 200 parts by weight of iron powder in the compound for the second resin layer shown in Table 2 was used for the second molded body 2, the holding power of the magnet-attached storage etc. was further improved, but it was confirmed that the mechanical strength was slightly inferior.

[0031] According to the first molded body 1 and the second molded body 2 described above, it is possible to use a magnetic storage device or a magnetic cleaning tool.

[0032] The present invention is not limited to the above-described embodiment, and various modifications can be made within the scope of the claims. For example, in the above-described embodiment, the first molded body 1 and the second molded body 2 are described as having a concealing gel coat layer 6, but depending on the member to which the invention is applied, the concealing gel coat layer 6 may be omitted. [Explanation of symbols]

[0033] 1 First molded body 2 Second molded body 3 Gelcoat layer (top gelcoat layer) 4 Magnetic layer 5 Resin layer 6 Concealing gel coat layer 7 Second resin layer

Claims

1. In a thermosetting resin molded article having at least a gel coat layer and a resin layer, a magnetic layer is provided between the gel coat layer and the resin layer, The magnetic layer is a matrix resin made of a thermosetting resin; A curing agent mainly composed of an organic peroxide; A thermosetting resin molded article, characterized in that 50 parts by weight or more of ferromagnetic powder or granules are blended with 100 parts by weight of the matrix resin.

2. In a thermosetting resin molded article having at least a gel coat layer and a resin layer, The resin layer is a matrix resin made of a thermosetting resin; A curing agent mainly composed of an organic peroxide; A thermosetting resin molded article, characterized in that 50 parts by weight or more of ferromagnetic powder or granules are blended with 100 parts by weight of the matrix resin.

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