Method for manufacturing molded body, laminate, vehicle, vehicle part, and method for manufacturing vehicle and vehicle part

Abstract

A method for manufacturing a molded body according to the present invention includes: a first step for preparing a laminate (3) by attaching to a resin member (2) a thermosetting resin sheet (1) comprising a resin layer formed from a thermosetting resin composition that includes a curable resin; and a second step for using a vacuum forming machine to form the laminate (3) to prepare a molded body, and curing the thermosetting resin sheet (1). The method for manufacturing a molded body according to the present invention also includes: the abovementioned first step; a fourth step for using a vacuum forming machine to form the laminate (3) to prepare a molded body; and a fifth step for curing the thermosetting resin sheet (1) in the molded body inside the vacuum forming machine. The laminate (3) to be formed using a vacuum forming machine according to the present invention includes a curable resin. The thermosetting resin sheet (1) comprising a resin layer formed from a thermosetting resin composition is attached to the resin member (2). A vehicle and a vehicle part according to the present invention comprise a molded body manufactured according to the method for manufacturing a molded body according to the present invention. A method for manufacturing a vehicle and a method for manufacturing a vehicle part according to the present invention include the method for manufacturing a molded body according to the present invention. The laminate according to the present invention is used in the method for manufacturing a molded body according to the present invention.

Description

Manufacturing method of molded body, laminate, vehicle and vehicle part, and manufacturing method of vehicle and vehicle part

[0001] The present invention relates to a method for manufacturing a molded body, a laminate, a vehicle and a vehicle part, and a method for manufacturing a vehicle and a vehicle part.

[0002] Conventionally, thermosetting resin sheets have been widely used in various fields because they can be easily manufactured into products with shapes suited to the purpose by various forming methods such as vacuum forming. For example, in the thermosetting covering sheet described in Patent Document 1, the thermosetting covering sheet is vacuum formed at a temperature of 60°C or 80°C. Then, a molded body obtained by forming the thermosetting covering sheet is attached to an adherend, and the molded body is heated to a temperature of 160°C to cure the thermosetting covering sheet.

[0003] Japanese Patent Application Publication No. 2-223445

[0004] However, when the adherend is a resin member, when the thermosetting covering sheet attached to the resin member is heated and cured, the thermosetting covering sheet needs to be cured at or below the heat resistance temperature of the resin member to prevent deformation of the resin member. Therefore, problems such as a long time required for curing the thermosetting covering sheet or insufficient curing of the thermosetting covering sheet may occur. On the other hand, if the heating temperature when curing the thermosetting covering sheet is increased in order to shorten the curing time of the thermosetting covering sheet, problems such as deformation of the resin member may occur.

[0005] Therefore, the present invention aims to provide a method for manufacturing a molded body that can shorten the curing time required for heating a thermosetting resin sheet attached to a resin member while suppressing deformation of the resin member, a laminate for molding with a vacuum forming machine, a laminate used in the method for manufacturing the molded body, a vehicle and vehicle part equipped with a molded body manufactured by the method for manufacturing the molded body, and a method for manufacturing the vehicle and vehicle part.

[0006] After extensive research, the present inventors discovered that the above-mentioned problems can be solved by curing a thermosetting resin sheet attached to a resin member in a vacuum forming machine, and thus completed the present invention. The gist of the present invention is as follows: [1] A method for producing a molded body, comprising: a first step of attaching a thermosetting resin sheet having a resin layer made of a thermosetting resin composition containing a curable resin to a resin member to produce a laminate; and a second step of molding the laminate using a vacuum forming machine to produce a molded body and curing the thermosetting resin sheet. [2] A method for producing a molded body according to [1] above, wherein in the second step, the thermosetting resin sheet is cured while producing the molded body. [3] A method for producing a molded body according to [2] above, comprising a third step of further promoting curing of the thermosetting resin sheet in the produced molded body in the vacuum forming machine. [4] The method for producing a molded body according to [3], wherein the third step further promotes curing of the thermosetting resin sheet of the molded body using a heater of the vacuum forming machine while the forming mold of the vacuum forming machine is in contact with the resin member. [5] The method for producing a molded body includes a first step of attaching a thermosetting resin sheet having a resin layer made of a thermosetting resin composition containing a curable resin to a resin member to produce a laminate, a fourth step of molding the laminate using a vacuum forming machine to produce a molded body, and a fifth step of curing the thermosetting resin sheet of the molded body in the vacuum forming machine. [6] The method for producing a molded body according to [5], wherein the fifth step curing the thermosetting resin sheet of the molded body using a heater of the vacuum forming machine while the forming mold of the vacuum forming machine is in contact with the resin member. [7] The method for producing a molded body according to any one of [1] to [4], wherein the thermosetting resin sheet further includes a transfer layer on the side of the resin layer opposite to the side where the resin member is attached. [8] The method for producing a molded article according to the above [7], wherein the transfer layer is peeled off from the thermosetting resin sheet before the second step. [9] The method for producing a molded article according to the above [7], wherein the transfer layer is peeled off from the thermosetting resin sheet after the second step.

[10] The method for producing a molded product according to [3] or [4] above, wherein the thermosetting resin sheet further comprises a transfer layer on the resin layer opposite to the side where the resin member is attached, and the transfer layer is peeled off from the thermosetting resin sheet after the third step.

[11] The method for producing a molded product according to [5] above, wherein the thermosetting resin sheet further comprises a transfer layer on the resin layer opposite to the side where the resin member is attached, and the transfer layer is peeled off from the thermosetting resin sheet before the fourth step.

[12] The method for producing a molded product according to [5] or [6] above, wherein the thermosetting resin sheet further comprises a transfer layer on the resin layer opposite to the side where the resin member is attached, and the transfer layer is peeled off from the thermosetting resin sheet after the fifth step.

[13] The method for producing a molded product according to any one of [7] to

[12] above, wherein the transfer layer contains at least one resin selected from the group consisting of a cycloolefin resin, a vinyl chloride resin, a polyester resin, a polypropylene resin, and a polyethylene resin.

[14] A method for producing a molded article according to any one of [1] to

[13] above, wherein the resin constituting the resin member is at least one resin selected from the group consisting of ABS (acrylonitrile-butadiene-styrene) resin, polypropylene resin, polyvinyl chloride resin, polyester resin, and polycarbonate resin.

[15] A method for producing a molded article according to any one of [1] to

[14] above, wherein the thermosetting resin composition contains at least one compound selected from the group consisting of blocked isocyanates and melamine-based compounds.

[16] A method for producing a molded article according to any one of [1] to

[15] above, wherein the thermosetting resin composition contains a (meth)acrylic polyol.

[17] A method for producing a molded article according to any one of [1] to

[16] above, wherein the resin layer is a colored layer.

[18] A laminate for molding with a vacuum forming machine, comprising a thermosetting resin sheet attached to a resin member, the thermosetting resin sheet having a resin layer made of a thermosetting resin composition containing a curable resin.

[19] A vehicle equipped with a molded article manufactured by the method for manufacturing a molded article according to any one of [1] to

[17] above.

[20] A vehicle part equipped with a molded article manufactured by the method for manufacturing a molded article according to any one of [1] to

[17] above.

[21] A method for manufacturing a vehicle, comprising the method for manufacturing a molded article according to any one of the above items [1] to

[17] .

[22] A method for manufacturing a vehicle part, comprising the method for manufacturing a molded article according to any one of the above items [1] to

[17] .

[23] A laminate used in the method for manufacturing a molded article according to any one of the above items [1] to

[17] .

[0007] According to the present invention, it is possible to provide a method for manufacturing a molded body that can shorten the curing time required for heating a thermosetting resin sheet attached to a resin member while suppressing deformation of the resin member, a laminate for molding in a vacuum forming machine, a laminate used in the method for manufacturing the molded body, a vehicle and vehicle part equipped with a molded body manufactured by the method for manufacturing the molded body, and a method for manufacturing the vehicle and vehicle part.

[0008] FIG. 1 is a schematic cross-sectional view of a thermosetting resin sheet used in a manufacturing method for a molded body according to an embodiment of the present invention. FIG. 2 is a schematic cross-sectional view of a thermosetting resin sheet from which a protective layer has been removed. FIG. 3 is a diagram illustrating attachment of a thermosetting resin sheet to a resin member. FIG. 4 is a schematic cross-sectional view of a laminate used in a manufacturing method for a molded body according to an embodiment of the present invention. FIG. 5 is a diagram illustrating molding of the laminate using a vacuum forming machine. FIG. 6 is a diagram illustrating molding of the laminate using a vacuum forming machine. FIG. 7 is a diagram illustrating molding of the laminate using a vacuum forming machine. FIG. 8 is a diagram illustrating heating of a molded body using a vacuum forming machine to promote curing of the thermosetting resin sheet. FIG. 9 is a schematic cross-sectional view showing a modified resin layer (paint layer). FIG. 10 is a schematic cross-sectional view of a modified thermosetting resin sheet. FIG. 11 is a schematic cross-sectional view of a modified thermosetting resin sheet. FIG. 12 is a schematic cross-sectional view of a modified thermosetting resin sheet.

[0009] [Method for manufacturing a molded body] (First embodiment) Hereinafter, a method for manufacturing a molded body according to a first embodiment of the present invention will be described with reference to the drawings. The method for manufacturing a molded body according to the first embodiment of the present invention includes a first step of manufacturing a laminate by attaching a thermosetting resin sheet having a resin layer (paint layer) made of a thermosetting resin composition containing a curable resin to a resin member, and a second step of molding the laminate and curing the thermosetting resin sheet using a vacuum forming machine.

[0010] (First Step) In the first step, a thermosetting resin sheet 1 having a resin layer (paint layer) 10 made of a thermosetting resin composition containing a curable resin is attached to a resin member 2 to produce a laminate 3. Note that if the thermosetting resin sheet is attached to the molded resin member after the resin member is molded, it becomes difficult to align the thermosetting resin sheet. However, in the method for manufacturing a molded body according to the first embodiment of the present invention, the thermosetting resin sheet is attached to the resin member before molding, which makes it easy to align the thermosetting resin sheet.

[0011] <Thermosetting resin sheet> As shown in Fig. 1, the thermosetting resin sheet 1 includes a resin layer (paint layer) 10 made of a thermosetting resin composition containing a curable resin. Also, as shown in Fig. 1, the thermosetting resin sheet 1 further includes a transfer layer 20 on the side of the resin layer (paint layer) 10 opposite to the side to which a resin member described below is attached. Furthermore, as shown in Fig. 1, the thermosetting resin sheet 1 further includes a protective layer 30 on the side of the resin layer (paint layer) 10 opposite to the transfer layer side.

[0012] In the method for producing a molded body according to the first embodiment of the present invention, the thermosetting resin sheet 1 includes a resin layer (paint layer) 10, a transfer layer 20, and a protective layer 30, as shown in Fig. 1, but the thermosetting resin sheet 1 may not include a protective layer, as shown in Fig. 10. Also, the thermosetting resin sheet 1 may not include a transfer layer, as shown in Fig. 11. Furthermore, the thermosetting resin sheet 1 may not include a transfer layer or a protective layer, and may consist of only the resin layer (paint layer) 10, as shown in Fig. 12.

[0013] <Resin Layer (Paint Layer)> The resin layer (paint layer) 10 in the thermosetting resin sheet 1 is formed from a thermosetting resin composition as described above. The thermosetting resin composition contains a curable resin. The curable resin preferably has a functional group, and the functional group is preferably a functional group that reacts with a reactive group (e.g., an isocyanate group) possessed by at least one compound selected from the group consisting of a blocked isocyanate and a melamine-based compound, which will be described later. Specific examples of the functional group include a hydroxyl group, a carboxyl group, and an amino group, with a hydroxyl group being preferred. The curable resin may have only one type of functional group, or two or more types. It is also preferable that two or more functional groups are contained in one molecule.

[0014] The content of the curable resin in the thermosetting resin composition is not particularly limited, but is preferably 40% by mass or more and 95% by mass or less, more preferably 50% by mass or more and 90% by mass or less, and even more preferably 60% by mass or more and 85% by mass or less, based on the total amount of the thermosetting resin composition.

[0015] Examples of the curable resin include (meth)acrylic resin, polycarbonate resin, polyester resin, and epoxy resin, and among these, (meth)acrylic resin is preferred.

[0016] Examples of the (meth)acrylic resin used in the thermosetting resin composition include (meth)acrylic resins having multiple functional groups. The functional groups are as described above, and the (meth)acrylic resin preferably has a hydroxyl group. The (meth)acrylic resin may have only one type of functional group, or may have two or more types. Therefore, the (meth)acrylic resin preferably contains a (meth)acrylic polyol having multiple hydroxyl groups, and more preferably contains an acrylic polyol.

[0017] The (meth)acrylic resin is preferably an acrylic polymer obtained by polymerizing a monomer mixture containing a (meth)acrylic acid ester monomer and a functional group-containing monomer having the above-mentioned functional group, such as a hydroxyl group, an amino group, or a carboxyl group. The monomer mixture may also contain a monomer other than the (meth)acrylic acid ester monomer and the functional group-containing monomer, such as a styrene derivative monomer. Note that (meth)acrylic means methacrylic or acrylic, and the same applies to other similar terms.

[0018] Examples of the (meth)acrylic acid ester monomer include (meth)acrylic acid ester monomers that do not have the above-mentioned functional group, such as alkyl (meth)acrylates having an alkyl group with approximately 1 to 18 carbon atoms, (meth)acrylates having an aromatic ring such as benzyl (meth)acrylate and phenoxydiethylene glycol (meth)acrylate, and 2-ethoxyethyl (meth)acrylate. Examples of functional group-containing monomers include (meth)acrylic acid ester monomers having a hydroxyl group such as 2-hydroxyethyl (meth)acrylate, (meth)acrylic acid ester monomers having an amino group such as 2-aminoethyl (meth)acrylate, and monomers having a carboxyl group such as (meth)acrylic acid. Examples of the (meth)acrylic resin include copolymers obtained by block or graft polymerization of the above-mentioned acrylic polymer with other monomers or polymers.

[0019] The content of the (meth)acrylic polyol in the thermosetting resin composition is not particularly limited, but is preferably 40% by mass or more and 90% by mass or less, more preferably 50% by mass or more and 85% by mass or less, and even more preferably 60% by mass or more and 80% by mass or less, based on the total amount of the thermosetting resin composition. By keeping the (meth)acrylic resin within the above range, the coatability and curability of the resin layer (paint layer) can be easily improved.

[0020] The thermosetting resin composition preferably contains a (meth)acrylic resin (hereinafter also referred to as a high molecular weight (meth)acrylic resin) that is solid, has a weight average molecular weight (Mw) of 50,000 or more and 1,000,000 or less, and has multiple functional groups. By including a (meth)acrylic resin with a weight average molecular weight within the above range, the resin layer (paint layer) 10 can be easily maintained in a consistent shape even before curing, making it easier to properly form on a transfer layer 20 or the like. Furthermore, the resin layer (paint layer) 10 can be easily imparted with tackiness and extensibility. The resin layer (paint layer) 10 has tackiness and extensibility, which improves shape conformability during vacuum molding and reduces color unevenness. Furthermore, a weight average molecular weight within the above range also facilitates increasing the hardness of the resin layer (paint layer) after curing. The weight-average molecular weight is preferably 100,000 or more and 500,000 or less, more preferably 120,000 or more and 400,000 or less. In this specification, the weight-average molecular weight (Mw) is measured by gel permeation chromatography (GPC) and is calculated as a standard polystyrene equivalent value. In addition, being solid means being solid at room temperature (23°C) and normal pressure (1 atmosphere).

[0021] The high molecular weight (meth)acrylic resin is preferably a (meth)acrylic polyol having a plurality of hydroxyl groups. As described above, the (meth)acrylic polyol can be obtained, for example, by polymerizing a monomer mixture containing a (meth)acrylic acid ester monomer and a hydroxyl group-containing monomer. In the thermosetting resin composition, the (meth)acrylic resin may be used alone or in combination of two or more.

[0022] The thermosetting resin composition may contain, as the curable resin, a resin having a weight-average molecular weight of less than 50,000 (hereinafter also referred to as a plasticizing resin) in addition to the high molecular weight (meth)acrylic resin described above. By containing a plasticizing resin having a low weight-average molecular weight in addition to a high molecular weight (meth)acrylic resin, the thermosetting resin composition can easily achieve a good balance of coatability, curability, tackiness, extensibility, etc. Furthermore, the wettability to resin members can be improved, thereby increasing the adhesive strength to resin members.

[0023] The plasticizing resin is preferably one that is compatible with the high-molecular-weight (meth)acrylic resin and has a thermosetting functional group. Examples of resins used for the plasticizing resin include (meth)acrylic resin, polycarbonate resin, polyester resin, and epoxy resin, and among these, (meth)acrylic resin or polycarbonate resin is preferred.

[0024] Examples of the (meth)acrylic resin used as the plasticizing resin include oligomers having functional groups such as hydroxyl groups, amino groups, and carboxyl groups. Examples of the (meth)acrylic resin used as the plasticizing resin include those described above for the (meth)acrylic resin, and preferably a (meth)acrylic polyol having multiple hydroxyl groups is used. Poly(meth)acrylates having carboxyl groups are also preferred. Polycarbonate polyols are preferred as the polycarbonate resin used as the plasticizing resin.

[0025] The weight average molecular weight of the plasticizing resin is preferably 450 or more and 30,000 or less, and more preferably 1000 or more and 20,000 or less. The plasticizing resin is desirably liquid at room temperature and normal pressure.

[0026] The plasticizing resin is preferably at least one of a (meth)acrylic polyol having a plurality of hydroxyl groups and a polycarbonate polyol.

[0027] The content of the plasticizing resin in the thermosetting resin composition relative to the content of the high molecular weight (meth)acrylic resin is, for example, 0 to 0.9, preferably 0.01 to 0.5, and more preferably 0.03 to 0.1, in mass ratio.

[0028] The thermosetting resin composition preferably contains at least one compound selected from the group consisting of blocked isocyanates and melamine-based compounds (hereinafter also referred to as compound (X)). Compound (X) is a curing agent for the curable resin.

[0029] Among the above compounds, blocked isocyanates are preferred as compound (X). Blocked isocyanates are compounds in which an isocyanate group is blocked with a protecting group. When exposed to high temperatures, the protecting group (blocking agent) is thermally dissociated and removed, causing a curing reaction between the resulting isocyanate group and a functional group in the curable resin (typically, a hydroxyl group of a polyol). Blocked isocyanates can be obtained, for example, by reacting an isocyanate compound having two or more isocyanate groups in one molecule with a blocking agent.

[0030] The isocyanate compound having two or more isocyanate groups in one molecule is not particularly limited, and examples thereof include tolylene diisocyanate, diphenylmethane diisocyanate, hexamethylene diisocyanate, pentamethylene diisocyanate, isophorone diisocyanate, xylylene diisocyanate, hydrogenated xylylene diisocyanate, and modified products thereof. Examples of blocking agents include pyrazole, phenols, oximes, lactams, and malonic acid esters. Among these, pyrazole is preferred. The content of the blocked isocyanate in the thermosetting resin composition is preferably adjusted so that the ratio of the number of functional groups in the curable resin to the number of isocyanate groups in the blocked isocyanate is preferably 0.4 to 1.8, more preferably 0.6 to 1.5.

[0031] The melamine-based compound is a compound having a melamine skeleton within the compound, and any compound capable of undergoing a dehydration condensation reaction may be used. Examples include alkylolated melamine derivatives such as monomethylolmelamine and hexamethylolmelamine obtained by reacting melamine with formaldehyde under alkaline conditions, compounds partially etherified by reacting an alkylolated melamine derivative with an alcohol, and mixtures thereof. The melamine-based compound may be either a monomer or a dimer or higher polymer, or a mixture thereof.

[0032] The thermosetting resin composition preferably contains a (meth)acrylic resin and a blocked isocyanate. By containing a (meth)acrylic resin and a blocked isocyanate, the resin layer (paint layer) 10 is more likely to have the desired flexibility and to have good adhesion to resin members and adhesive strength. In addition, after curing by heat curing, it is easier to achieve high hardness, and the scratch resistance of the cured paint is also improved.

[0033] The content of compound (X) in the thermosetting resin composition is preferably 5% by mass or more, more preferably 10% by mass or more, and even more preferably 15% by mass or more, based on the total amount of the thermosetting resin composition. When the content of compound (X) is equal to or greater than the above-mentioned lower limit, the thermosetting resin composition can be sufficiently cured, making it easier to obtain a resin layer (paint layer) 10 with excellent strength. Furthermore, from the viewpoint of being able to contain a certain proportion of the thermosetting resin and colorant described below, the content of compound (X) is preferably 50% by mass or less, more preferably 45% by mass or less, and even more preferably 40% by mass or less, based on the total amount of the thermosetting resin composition. Note that the thermosetting resin composition may be diluted with a volatile component such as a solvent, as described below. In this specification, the content (mass%) of each component in the thermosetting resin composition refers to the value based on the solids content excluding the volatile components.

[0034] In addition to the curable resin and curing agent, the thermosetting resin composition may contain appropriate components according to the performance required for the coating formed from the resin layer (paint layer). For example, when the coating formed from the resin layer (paint layer) is to be a colored coating, a colorant such as a pigment, dye, or luster material may be added to make the resin layer (paint layer) a colored layer. When the coating formed from the resin layer (paint layer) is to be a heat-shielding coating, a heat-shielding material may be added to the thermosetting resin composition, making the resin layer (paint layer) a heat-shielding layer. The resin layer (paint layer) may also contain components other than those described above, such as additives other than those described above. Examples of additives include crosslinking agents, dispersants, inorganic fillers other than pigments and luster materials, antioxidants, antioxidants, and rust inhibitors. Furthermore, the resin layer (paint layer) 10 may be composed of a clear layer, as described below. Among these, it is preferable that the thermosetting resin composition contains at least a colorant.

[0035] Examples of pigments used as colorants include, but are not limited to, metal oxide pigments such as titanium oxide and iron oxide; inorganic pigments such as carbon black, clay, kaolin, barium sulfate, barium carbonate, calcium carbonate, talc, silica, and alumina white; and organic pigments such as azo pigments, quinacridone pigments, diketopyrrolopyrrole pigments, perylene pigments, perinone pigments, benzimidazolone pigments, vat pigments, isoindoline pigments, isoindolinone pigments, metal chelate azo pigments, phthalocyanine pigments, indanthrone pigments, dioxane pigments, and indigo pigments. Known dyes can be used, including azo dyes, anthraquinone dyes, indigoid dyes, and stilbene dyes. The lustrous material is a compound that can impart lustrous properties to the resin layer (paint layer) 10 and can impart the property of exhibiting gloss when observed from multiple directions. The glittering material is not particularly limited, but examples thereof include compounds in which a titanium oxide layer is provided on the surface of natural mica, synthetic mica, alumina flakes, glass flakes, etc.

[0036] The resin layer (paint layer) 10 preferably contains at least one of a pigment or a luster material as a colorant, and more preferably contains a pigment. It is also preferable that the resin layer (paint layer) 10 contains both a pigment and a luster material.

[0037] The content of the colorant in the thermosetting resin composition is not particularly limited, but is, for example, about 0.1 to 25% by mass, preferably 0.3 to 20% by mass, and more preferably 0.5 to 12% by mass.

[0038] In addition to the above-described additives such as a colorant and a heat-shielding material, the thermosetting resin composition may also contain additives such as an inorganic filler, a curing catalyst, a curing accelerator, a surface conditioner, an antifoaming agent, a crosslinking agent, a dispersant, an antioxidant, and an antioxidant, as appropriate.

[0039] In the method for producing a molded body according to the first embodiment of the present invention, the resin layer (paint layer) 10 consists of a single layer, as shown in Fig. 1. However, as shown in Fig. 9, the resin layer (paint layer) 10 may consist of two resin layers 11 and 12, or, although not shown, the resin layer (paint layer) may consist of three or more resin layers. When the resin layer (paint layer) has a multilayer structure, various functions can be imparted to the coating formed from the resin layer (paint layer).

[0040] In the case where the resin layer (paint layer) has a multilayer structure, each layer may be made of the above-mentioned thermosetting resin composition. Each layer may contain a colorant as described above to form a colored layer, a heat-shielding material to form a heat-shielding layer, or a clear layer that does not substantially contain a colorant.

[0041] In the case of a multilayer structure, the resin layer (paint layer) preferably has at least a colored layer and a clear layer. When a colored layer and a clear layer are present, the clear layer and the colored layer are preferably arranged in this order from the transfer layer side. With this layer configuration, when the thermosetting resin sheet is attached to a resin member, the colored layer and the clear layer are arranged in this order from the resin member side. For example, as shown in FIG. 9 , if the resin layer (paint layer) 10 consists of two resin layers 11 and 12, the resin layer 11 is the clear layer and the resin layer 12 is the colored layer. By having a colored layer, the resin layer (paint layer) can color the object to be painted by the paint formed by the resin layer (paint layer). Furthermore, providing a clear layer in addition to the colored layer can protect the colored layer and impart gloss to the colored layer. The colored layer preferably contains a pigment as a colorant, and therefore, it is particularly preferable for the resin layer (paint layer) to have a clear layer and a colored layer.

[0042] Both the colored layer and the clear layer may be made of the above-described thermosetting resin composition, and the thermosetting resin composition for the colored layer may contain a colorant as described above. Furthermore, when a (meth)acrylic resin is used as the curable resin, the thermosetting resin composition for the colored layer may contain at least a high molecular weight (meth)acrylic resin, but preferably contains both a high molecular weight (meth)acrylic resin and a plasticizing resin. On the other hand, the clear layer is a transparent layer and may have sufficient transparency so that the color of the colored layer can be seen from the outside through the clear layer. For example, it may have a transmittance of 80% or more for light with a wavelength of 450 nm. The clear layer is preferably a coating film that does not contain a colorant, but may contain a small amount of colorant as long as it does not impair its function. Furthermore, when a (meth)acrylic resin is used as the curable resin, the thermosetting resin composition for the clear layer may contain at least a high molecular weight (meth)acrylic resin, but in that case, it may or may not contain a plasticizing resin.

[0043] Of course, when the resin layer (paint layer) has a multi-layer structure, it is not limited to a two-layer structure of a clear layer and a colored layer, and various laminated structures are possible, such as a three-layer or more structure with two or more colored layers and one or more clear layers, or a structure consisting of two colored layers without the clear layer. Also, two or more clear layers may be provided. Furthermore, a heat-shielding layer or the like may be provided between the clear layer and the colored layer, resulting in a three-layer or more structure.

[0044] The thickness of the resin layer (paint layer) 10 is not particularly limited, but is, for example, 20 μm to 200 μm, preferably 30 μm to 100 μm. Furthermore, when a colored layer and a clear layer are provided on the resin layer (paint layer), the thickness of the colored layer is not particularly limited, but is, for example, 10 μm to 100 μm, preferably 15 μm to 50 μm. Furthermore, the thickness of the clear layer is not particularly limited, but is, for example, 10 μm to 100 μm, preferably 15 μm to 50 μm.

[0045] <Transfer Layer> The transfer layer 20 is a member that protects the resin layer (paint layer) 10 from scratches and adhesion of foreign matter, and also serves as a support when the resin layer (paint layer) 10 is attached to a resin member.

[0046] The transfer layer 20 may be formed from a resin film. Examples of resins used in the resin film for the transfer layer include thermoplastic resins. Examples of resins used in the resin film include polyolefin resins such as cycloolefin resins, polypropylene resins, and polyethylene resins, ethylene vinyl acetate resins (EVA), polyester resins, polyamide resins, acrylonitrile butadiene styrene resins, polycarbonate resins, acrylic resins, fluororesins, vinyl chloride resins, and tetrafluoroethylene resins. Of these, cycloolefin resins, vinyl chloride resins, polyester resins, polypropylene resins, and polyethylene resins are preferred. Of these resins, polypropylene resins and polyethylene resins are more preferred, and polyethylene resins are even more preferred.

[0047] The polypropylene resin may be homopropylene, or may be a copolymer of propylene, such as random polypropylene, with a small amount (for example, 10% by mass or less) of another α-olefin. Examples of the other α-olefin include linear α-olefins having 1 to 12 carbon atoms, such as ethylene, 1-butene, 1-pentene, 4-methyl-1-pentene, 1-hexene, 1-octene, 1-nonene, and 1-decene. Examples of the polyethylene resin include low-density polyethylene (LDPE, density: 0.930 g / cm). ３ less than 0.930 g / cm), medium density polyethylene (MDPE, density: 0.930 g / cm ３ 0.942g / cm or more ３ less than 0.942 g / cm), high density polyethylene (HDPE, density: 0.942 g / cm ３ and linear low density polyethylene (LLDPE).

[0048] The resin film constituting the transfer layer 20 may be a single-layer film consisting of one single layer, or a multilayer film consisting of two or more layers. Furthermore, in the resin film constituting the transfer layer 20, the resin contained in the resin film may be used alone, or two or more types may be used in combination. When two or more types of resins are used in combination, a multilayer film may be formed by using different types of resins in each layer. Furthermore, a single-layer film may be formed from a mixture of two or more resins, or one or more layers of a multilayer film may be formed from a mixture of two or more resins. In the case of a multilayer film, at least one layer is preferably either a polypropylene resin layer or a polyethylene resin layer, and a polyethylene resin layer is more preferred. For example, a multilayer film containing a polyethylene resin layer may be a multilayer film consisting of a polyethylene resin layer and an EVA layer. The resin film used in the transfer layer may be a stretched resin film or a non-stretched resin film, but a non-stretched resin film is preferred.

[0049] The transfer layer 20 may have at least one surface that has been release-treated with a release agent such as a silicone-based release agent or a fluorine-based release agent. When the transfer layer 20 is release-treated, it is preferable that the release-treated surface constitutes the surface on the resin layer (paint layer) side. The release treatment of the transfer layer 20 makes it easier to peel it from the resin layer (paint layer) 10. However, the transfer layer 20 does not need to be release-treated as long as it can be peeled from the resin layer (paint layer) 10. The thickness of the transfer layer 20 is not particularly limited, but is, for example, 10 μm or more and 1000 μm or less, preferably 30 μm or more and 700 μm or less, and more preferably 50 μm or more and 500 μm or less.

[0050] <Protective Layer> The protective layer 30 is a member that protects the resin layer (paint layer) 10 from scratches and adhesion of foreign matter. The protective layer 30 is preferably formed from a resin film. Examples of resins used in the resin film for the protective layer include thermoplastic resins. Examples of resins used in the resin film can be appropriately selected from the resins exemplified for the transfer layer, and preferred examples include cycloolefin resins, vinyl chloride resins, polyester resins, polypropylene resins, and polyethylene resins. Among these resins, polypropylene resins and polyethylene resins are more preferred, and polyethylene resins are even more preferred.

[0051] The resin film forming the protective layer 30 may be a single-layer film consisting of one layer, or may be a multilayer film consisting of two or more layers. Furthermore, in the resin film constituting the protective layer 20, the resin contained in the resin film may be used alone or in combination of two or more types. In the case of a multilayer film, it is preferable that at least one layer is either a polypropylene resin layer or a polyethylene resin layer, and a polyethylene resin layer is more preferable. For example, a multilayer film containing a polyethylene resin layer may be a multilayer film consisting of a polyethylene resin layer and an EVA layer. The resin film used in the protective layer 20 may be a stretched resin film or a non-stretched resin film, but a non-stretched resin film is preferable.

[0052] The protective layer 20 may have at least one surface that has been release-treated with a release agent such as a silicone-based release agent or a fluorine-based release agent. When the protective layer is release-treated, it is preferable that the release-treated surface constitutes the surface on the resin layer (paint layer) side. By being release-treated, the protective layer can be easily peeled from the resin layer (paint layer). However, the protective layer does not need to be release-treated as long as it can be peeled from the resin layer (paint layer).

[0053] The thickness of the protective layer 20 is not particularly limited, but is, for example, 10 μm or more and 1000 μm or less, preferably 30 μm or more and 700 μm or less, and more preferably 50 μm or more and 500 μm or less.

[0054] <Method for manufacturing thermosetting resin sheet> The method for manufacturing a thermosetting resin sheet is not particularly limited, and it can be manufactured by a known method. For example, a thermosetting resin composition is prepared, and the prepared thermosetting resin composition is applied to a transfer layer and dried as needed to form a resin layer (paint layer). In addition, when the thermosetting resin sheet has a protective layer, the thermosetting resin composition is applied to the protective layer and dried as needed to form a resin layer (paint layer), and a transfer layer may be further laminated to the resin layer (paint layer) formed on the obtained protective layer to obtain a thermosetting resin sheet. In addition, when applying the thermosetting resin composition to the transfer layer or protective layer, the thermosetting resin composition may be appropriately diluted with a solvent or the like. Examples of solvents include ethyl acetate, butyl acetate, and toluene. In addition, when the resin layer (paint layer) is multilayered, it may be formed by sequentially forming and laminating each layer. For example, when a clear layer and a colored layer are provided, the clear layer and the colored layer may be laminated in this order on the transfer layer. Furthermore, when the thermosetting resin sheet has a protective layer, the thermosetting resin sheet may be obtained by laminating a colored layer formed on the protective layer and a clear layer formed on the transfer layer.

[0055] <Resin Member> The resin member is a flat resin plate. The resin constituting the resin member is not particularly limited as long as it can be formed by vacuum forming, but thermoplastic resin is preferred. Examples of thermoplastic resins that can be used as the resin member include ABS (acrylonitrile-butadiene-styrene) resin, PP (polypropylene) resin, PVC (polyvinyl chloride) resin, polyester resin, polycarbonate resin, etc. These resins can be used alone or in combination of two or more. Among these resins, ABS resin is preferred. These resins may be deformed at the curing temperature of the thermosetting resin sheet 1. However, in the present invention, by forming the laminate in a vacuum forming machine and curing the thermosetting resin sheet 1, it is possible to prevent the resin member from deforming from the desired shape even when the curing temperature is increased.

[0056] The thickness of the resin member is not particularly limited as long as it is a thickness that allows vacuum forming, but is usually 30 to 5000 μm, and preferably 100 to 3000 μm.

[0057] <Attachment> When the thermosetting resin sheet 1 includes the protective layer 30, the protective layer 30 is peeled off from the thermosetting resin sheet 1 as shown in FIG. 2 before attaching the thermosetting resin sheet 1 to the resin member.

[0058] The thermosetting resin sheet 1 can be attached to the resin member 2 by, for example, pressing the thermosetting resin sheet 1 onto the resin member 2 with a pressure roll 50, as shown in Fig. 3. If the thermosetting resin sheet does not have adhesive properties to the resin member, the thermosetting resin sheet can be attached to the resin member by a method such as thermal lamination, hot melt lamination, non-solvent lamination, wet lamination, or dry lamination.

[0059] After attaching the thermosetting resin sheet 1 to the resin member 2, the transfer layer 20 is peeled off from the thermosetting resin sheet 1 to obtain the laminate 3 shown in FIG. 4 . In this case, the transfer layer 20 is peeled off from the thermosetting resin sheet 1 before the second step described below, and before the fourth step or the fifth step described below. This also helps prevent the transfer layer from shrinking and wrinkling due to heating. This facilitates gas escape from the thermosetting resin sheet 1 during curing, facilitating proper thermosetting. However, the transfer layer 20 may be peeled off from the thermosetting resin sheet after the second step described below and after the fifth step described below (or after the third step, if there is a third step described below). This prevents dust and other particles from adhering to the surface of the thermosetting resin sheet during molding. In this case, the thermosetting resin sheet is heated to promote curing of the thermosetting resin sheet in the third step described below, so it is preferable that the transfer layer have excellent heat resistance. From this viewpoint, when the transfer layer is peeled off from the thermosetting resin sheet after the third step described below, it is preferable that the resin constituting the transfer layer is at least one resin selected from the group consisting of cycloolefin resin, polypropylene resin, and polyethylene resin.

[0060] (Second Step) In the second step, a vacuum forming machine is used to form the laminate to produce a molded body, and the thermosetting resin sheet is cured. In this embodiment, as described below, the second step is a step of curing the thermosetting resin sheet while producing the laminate. It can be said that the second step (Step 1) of forming the laminate to produce a molded body and the second step (Step 2) of curing the thermosetting resin sheet are performed simultaneously. As shown in FIG. 5 , the vacuum forming machine 100 includes a forming die 110, a heater 120, and a clamp 130. The forming die 110 is movable in the vertical direction and pushes up the softened laminate 3, applying vacuum suction to the surface to form the laminate 3. The forming die 110 is made of, for example, aluminum or zinc alloy, which has mechanical strength, is relatively easy to cut, finish, and polish, has a low specific gravity, good thermal conductivity, a low melting point, and is easily castable. The forming die 110 has vacuum holes (not shown) at the locations where the laminate 3 comes into contact during molding. The heater 120 emits infrared rays to heat the laminate 3, softening the resin member 2 of the laminate 3 and curing the thermosetting resin sheet 1 of the laminate 3. As the heater 120, for example, a sheathed heater in which nichrome wire and insulating powder are filled in a metal tube, a porcelain heater, or the like is used. The clamp 130 holds the laminate 3 to prevent it from falling off during molding of the laminate 3. The second step will be described in detail below.

[0061] As shown in FIG. 5 , the laminate 3 is placed in the vacuum forming machine 100 with the thermosetting resin sheet 1 facing the heater and the resin member 2 facing the mold, and the laminate 3 is fixed with a clamp 130. Then, as shown in FIG. 5 , the heater 120 is used to heat the laminate 3 and soften the resin member in the laminate 3. At this time, the laminate 3 is heated to the molding temperature described below. Next, as shown in FIG. 6 , the heater 120 is retracted, and pressurized air (low-pressure air) is blown from below the laminate 3 to prevent the bottom wall thickness of the laminate 3 from increasing. Then, as shown in FIG. 7 , the mold 110 moves upward, pushing up the softened laminate 3 and vacuum-suctioning it to adhere it to the surface, thereby shaping the laminate 3. As a result, the laminate 3 is molded, and the thermosetting resin sheet 1 is cured to produce a molded product. The distance between the heater 120 and the laminate 3 is preferably 2 cm or more and 20 cm or less. If the distance between the heater 120 and the laminate 3 is too small, only the portions of the laminate 3 closest to the heater 120 may be heated, which may result in deterioration of the thermosetting resin sheet 1. On the other hand, if the distance between the heater 120 and the laminate 3 is too large, it may take a long time to cure the entire thermosetting resin sheet.

[0062] Because the laminate 3 is heated from the thermosetting resin sheet side of the laminate 3 by infrared rays radiated from the heater 120, the temperature of the thermosetting resin sheet 1 in the laminate 3 becomes higher than the temperature of the resin member 2. Furthermore, because the laminate 3 is in contact with the molding die 110 on the resin member side, the temperature of the resin member 2 becomes lower than the temperature of the thermosetting resin sheet 1. Therefore, heating by the heater 120 and contact with the molding die can make the temperature of the thermosetting resin sheet 1 in the laminate 3 higher than the temperature of the resin member 3. This makes it possible to increase the temperature of the thermosetting resin sheet 1 in the laminate 3 while suppressing an increase in the temperature of the resin member 2, thereby shortening the curing time required for heating and curing the thermosetting resin sheet 1 attached to the resin member 2 while suppressing deformation of the resin member 2.

[0063] The heater 120 may be retracted during molding of the laminate, as long as molding can be performed within the molding temperature range described below. The heater 120 may not be retracted during molding of the laminate, as long as molding can be performed within the molding temperature range described below.

[0064] The molding temperature when molding the laminate 3 is preferably 90 to 200°C. When the molding temperature of the laminate 3 is 90 to 200°C, the laminate 3 can be made to follow the shape of the molding die 110, allowing the laminate 3 to be sufficiently shaped, and excessive softening of the resin member 3 can be suppressed. From this viewpoint, the molding temperature of the thermosetting resin sheet 1 of the laminate 3 when molding the laminate 3 is more preferably 90 to 200°C, and even more preferably 90 to 160°C.

[0065] (Third Step) The method for manufacturing a molded body according to the first embodiment of the present invention may further include a third step in which the curing of the thermosetting resin sheet in the molded body produced as described above is further accelerated in a vacuum forming machine. This allows the thermosetting resin sheet 1 in the laminate 3 to be further cured. At this time, as shown in FIG. 8 , the forming die 110 of the vacuum forming machine 100 is kept pressed against the resin member 2, and the heater 120 of the vacuum forming machine 100 can be used to further accelerate the curing of the thermosetting resin sheet in the molded body 4 while in contact with the resin member 2. This allows the temperature of the thermosetting resin sheet 1 in the molded body 4 to be increased while suppressing a rise in the temperature of the resin member 2. This allows the curing of the thermosetting resin sheet 1 attached to the resin member 2 to be further accelerated in a short time while suppressing deformation of the resin member 2. Note that if the heating temperature in the third step is lower than the heat resistance temperature of the resin member 2, the forming die 110 of the vacuum forming machine 100 does not need to be in contact with the resin member 2. In the third step, the heater 120 is moved from the retracted position to a position where it can heat the molded body 4, and the molded body is heated by the heater 120. If the heater 120 is not retracted in the second step-1 and the second step-2, the molded body 4 may be heated by the heater 120 as is after the laminate 3 is molded. The distance between the heater 120 and the molded body 4 is preferably 2 cm or more and 20 cm or less. If the distance between the heater 120 and the molded body 4 is too small, only the portion of the molded body 4 closest to the heater 120 may be heated, which may result in deterioration of the thermosetting resin sheet 1. On the other hand, if the distance between the heater 120 and the molded body 4 is too large, it may take a long time to cure the entire thermosetting resin sheet.

[0066] The curing temperature for further promoting the curing of the thermosetting resin sheet 1 in the molded body 4 is preferably 120 to 180°C. A curing temperature of 120 to 180°C allows the curing of the thermosetting resin sheet 1 to further proceed while further suppressing deformation of the resin member 2. From this perspective, the curing temperature is more preferably 120 to 180°C, and even more preferably 130 to 160°C. Specifically, the curing temperature of the molded body 4 is the temperature of the surface of the molded body 4 facing the thermosetting resin sheet. Furthermore, the curing time for further promoting the curing of the thermosetting resin sheet 1 in the molded body 4 is preferably 1 to 30 minutes. A curing time of 1 to 30 minutes allows the curing of the thermosetting resin sheet in the molded body 4 to proceed more sufficiently and increases the production efficiency of the molded body. From this perspective, the curing time is more preferably 1 to 30 minutes, and even more preferably 5 to 20 minutes.

[0067] The manufacturing method of the molded body of the first embodiment of the present invention is merely one example of a manufacturing method of the molded body of the present invention, and therefore the manufacturing method of the molded body of the present invention is not limited to the manufacturing method of the molded body of the first embodiment of the present invention. The third step may be omitted. Furthermore, if the third step is omitted, it is desirable to completely cure the thermosetting resin sheet 1 in the second step-2. However, if the third step is included, it is not necessary to completely cure the thermosetting resin sheet 1 in the second step-2; the thermosetting resin sheet 1 may be semi-cured or partially cured. The thermosetting resin sheet 1 may then be completely cured in the third step. Furthermore, after the molded body is removed from the vacuum forming machine, the curing of the molded body may be further advanced. After the molded body is removed from the vacuum forming machine, it is preferable to cure the molded body at a temperature lower than the molding temperature in the second step-1 or the curing temperature in the third step to prevent deformation of the resin member.

[0068] Second Embodiment Hereinafter, a method for manufacturing a molded body according to a second embodiment of the present invention will be described with reference to the drawings. Explanations of parts common to the method for manufacturing a molded body according to the first embodiment of the present invention will be omitted, and differences from the method for manufacturing a molded body according to the first embodiment of the present invention will be mainly described. The method for manufacturing a molded body according to the second embodiment of the present invention includes a first step of manufacturing a laminate by attaching a thermosetting resin sheet having a resin layer (paint layer) made of a thermosetting resin composition containing a curable resin to a resin member, a fourth step of molding the laminate using a vacuum forming machine to manufacture a molded body, and a fifth step of curing the thermosetting resin sheet in the molded body manufactured in the vacuum forming machine.

[0069] (First Step) In the first step, a thermosetting resin sheet 1 having a resin layer (paint layer) 10 made of a thermosetting resin composition containing a curable resin is attached to a resin member 2 to produce a laminate 3. The first step in the method for producing a molded body of the second embodiment of the present invention is common to the first step in the method for producing a molded body of the first embodiment of the present invention, and therefore a description of the first step in the method for producing a molded body of the second embodiment of the present invention will be omitted.

[0070] (Fourth Step) In the fourth step, the laminate is molded using a vacuum forming machine to produce a molded body. As shown in FIG. 5, the laminate 3 is placed in the vacuum forming machine 100 so that the thermosetting resin sheet 1 faces the heater and the resin member 2 faces the mold, and the laminate 3 is fixed with a clamp 130. Then, as shown in FIG. 5, the heater 120 is used to heat the laminate 3 and soften the resin member in the laminate 3. At this time, the laminate 3 is heated to a molding temperature described below. Next, as shown in FIG. 6, the heater 120 is retracted, and pressurized air (slightly compressed air) is blown from below the laminate 3 to prevent the bottom wall thickness of the laminate 3 from increasing. Then, as shown in FIG. 7, the mold 110 moves upward, pushing up the softened laminate 3 and vacuum-suctioning it to adhere to the surface, thereby shaping the laminate 3. As a result, the laminate 3 is molded, and a molded body is produced.

[0071] The molding temperature when molding the laminate 3 is preferably 90 to 115°C. When the molding temperature of the laminate 3 is 90 to 115°C, the laminate 3 can be made to follow the shape of the molding die 110, allowing the laminate 3 to be sufficiently shaped, and excessive softening of the resin member 3 can be suppressed. From this viewpoint, the molding temperature of the thermosetting resin sheet 1 of the laminate 3 when molding the laminate 3 is more preferably 90 to 110°C, and even more preferably 90 to 105°C.

[0072] (Fifth Step) In the fifth step, the thermosetting resin sheet 1 in the molded body 4 is cured in a vacuum forming machine. At this time, as shown in FIG. 8 , it is preferable to keep the forming die 110 of the vacuum forming machine 100 pressed against the resin member 2, and use the heater 120 of the vacuum forming machine 100 to cure the thermosetting resin sheet in the molded body 4 while in contact with the resin member 2. This allows the temperature of the thermosetting resin sheet 1 in the molded body 4 to be increased while suppressing an increase in the temperature of the resin member 2. This allows the curing of the thermosetting resin sheet 1 attached to the resin member 2 by heating to proceed while suppressing deformation of the resin member 2. In the fifth step, the heater 120, which had been retracted, is moved to a position where it can heat the molded body 4, and the molded body is heated by the heater 120. If the heater 120 was not retracted in the fourth step, the molded body 4 may be heated by the heater 120 immediately after the laminate 3 is formed. The distance between the heater 120 and the molded body 4 is preferably 2 cm or more and 20 cm or less. If the distance between the heater 120 and the molded body 4 is too small, only the portion of the molded body 4 closest to the heater 120 may be heated, which may deteriorate the thermosetting resin sheet 1. On the other hand, if the distance between the heater 120 and the molded body 4 is too large, it may take a long time to cure the entire thermosetting resin sheet.

[0073] The curing temperature for curing the thermosetting resin sheet 1 in the molded body 4 is preferably 120 to 180°C. A curing temperature of 120 to 180°C allows the thermosetting resin sheet 1 to be cured while further suppressing deformation of the resin member 2. From this perspective, the curing temperature is more preferably 120 to 180°C, and even more preferably 130 to 160°C. Specifically, the curing temperature of the molded body 4 is the temperature of the surface of the molded body 4 on the thermosetting resin sheet side. Furthermore, the curing time for curing the thermosetting resin sheet 1 in the molded body 4 is preferably 1 to 30 minutes. A curing time of 1 to 30 minutes allows the thermosetting resin sheet in the molded body 4 to be sufficiently cured, and can increase the production efficiency of the molded body. From this perspective, the curing time is more preferably 1 to 30 minutes, and even more preferably 5 to 20 minutes.

[0074] The method for manufacturing the molded body of the second embodiment of the present invention is merely one example of the method for manufacturing the molded body of the present invention, and therefore the method for manufacturing the molded body of the present invention is not limited to the method for manufacturing the molded body of the second embodiment of the present invention.

[0075] The molded article produced by the molded article production method of the present invention can be used for various applications. The molded article produced by the molded article production method of the present invention is used, for example, for vehicles such as automobiles and transportation equipment, vehicle parts, electrical appliances, miscellaneous goods, heavy machinery, ships, aircraft, etc., exterior materials for exterior walls or roofs of houses and buildings, bridges, steel frames, plants, wind power generation blades, etc. Examples of vehicle parts include vehicle interior materials and vehicle exterior materials. Among these, vehicles and vehicle parts are preferred, vehicle parts are more preferred, and vehicle exterior materials are even more preferred. Examples of vehicle exterior materials include aero parts, hoods, roofs, door panels, bumpers, fuel filler panels, trunk lids, rear gates, etc.

[0076] [Laminate] The laminate of the present invention is a laminate for molding with a vacuum molding machine, and is formed by attaching a thermosetting resin sheet having a resin layer (paint layer) made of a thermosetting resin composition containing a curable resin to a resin member. The laminate of the present invention is also used in the method for manufacturing a molded article of the present invention. Note that the laminate of the present invention has already been described in the section on the method for manufacturing a molded article, so description of the laminate of the present invention will be omitted.

[0077] [Vehicles, Vehicle Parts] [Vehicles, Vehicle Parts, and Manufacturing Methods Thereof] The vehicle and vehicle part of the present invention are equipped with a molded body manufactured by the molded body manufacturing method of the present invention. For example, the vehicle part of the present invention is an aero part, a side mirror, or a roof box manufactured by the molded body manufacturing method of the present invention. Furthermore, the vehicle of the present invention is a vehicle equipped with a vehicle part such as an aero part manufactured by the molded body manufacturing method of the present invention. Furthermore, since the vehicle and vehicle part of the present invention are equipped with a molded body manufactured by the molded body manufacturing method of the present invention, the vehicle manufacturing method and vehicle part manufacturing method of the present invention include the molded body manufacturing method of the present invention.

[0078] The present invention will be explained in more detail below with reference to examples, but the present invention is not limited to these examples in any way.

[0079] The evaluation methods in this example are as follows. (Curing time of thermosetting resin sheet) The curing time until the thermosetting resin sheet of the manufactured molded article was sufficiently cured was investigated and evaluated as follows. A: The curing time of the thermosetting resin sheet was less than 30 minutes. B: The curing time of the thermosetting resin sheet was longer than 30 minutes.

[0080] (Curing of Thermosetting Resin Sheet) The state of curing of the thermosetting resin sheet of the produced molded article was visually observed and evaluated as follows: A: The thermosetting resin sheet was sufficiently cured. B: The thermosetting resin sheet was insufficiently cured.

[0081] (Presence or Absence of Deformation in Molded Article) The produced molded article was visually inspected for the presence or absence of deformation in the molded article, and rated as follows: A: No deformation in the molded article. B: Deformation in the molded article.

[0082] The components of the transfer layer film, protective layer film, and resin layer used in the examples and comparative examples are as follows: <Transfer layer film and protective layer film> Convenience PE: Unstretched polyethylene / EVA multilayer film ("Convenience PE" manufactured by Okamoto Corporation, thickness 200 μm)

[0083] <Polyol Resins> Acrylic polyol resin (1): weight average molecular weight 250,000, hydroxyl value 80 mgKOH / g, solid content (NV) = 23.3 mass% (solvent: ethyl acetate) Acrylic polyol resin (2): weight average molecular weight 250,000, hydroxyl value 170 mgKOH / g, solid content (NV) = 29.6 mass% (solvent: ethyl acetate)

[0084] <Plasticizing resin> Polycarbonate diol: hydroxyl value 204 to 244 mg KOH / g, weight average molecular weight 500, "PH-50", manufactured by UBE Co., Ltd.

[0085] <Blocked isocyanate> Mitsui Chemicals, Inc., "Takenate B-882N," hexamethylene diisocyanate-based blocked isocyanate curing agent (HDI-based), blocking agent type: 3,5-dimethylpyrazole (DMP), solid content (NV) = 70%, solvent: petroleum naphtha, thermal dissociation temperature = 120°C

[0086] <Urethanization catalyst> "XK-639", manufactured by Kusumoto Chemicals Co., Ltd., solid content (NV) = 100%

[0087] <Pigment (colorant)> "NSP-UP 841B" manufactured by Nihon Bix Co., Ltd., effective pigment concentration = 9 mass%, solid content concentration (NV) = 9.0 mass%, solvent: MEK

[0088] <Glittering material (colorant)> "Xirallic T60-10 WNT Crystal Silver" manufactured by Merck, solid content (NV) = 100% by mass

[0089] <Resin Members> Resin member (1): ABS resin, thickness = 3000 μm Resin member (2): PVC resin, thickness = 3000 μm Resin member (3): PP resin, thickness = 3000 μm

[0090] [Preparation of Thermosetting Resin Compositions A and B] Each component was added in the proportions shown in Table 1, and ethyl acetate was added as a solvent to prepare coating materials of thermosetting resin compositions A and B so that the solid content concentration was 30 mass %.

[0091] [Preparation of Thermosetting Resin Sheet] Thermosetting resin composition A was applied to the surface of the film for the transfer layer using an applicator, followed by a pre-drying process at a drying temperature of 60°C and a drying time of 30 minutes, followed by a main drying process at a drying temperature of 90°C and a drying time of 30 minutes, forming a clear layer with a thickness of 30 μm on the transfer layer. Next, thermosetting resin composition B was applied to the surface of the film for the protective layer using an applicator, followed by a pre-drying process at a drying temperature of 60°C and a drying time of 30 minutes, followed by a main drying process at a drying temperature of 90°C and a drying time of 30 minutes, forming a colored layer with a thickness of 30 μm on the film for the protective layer. The clear layer on the transfer layer and the colored layer on the protective layer were bonded together and laminated at 25°C to obtain a thermosetting resin sheet in which the transfer layer, clear layer, colored layer, and protective layer were laminated in this order. The above evaluations were performed using the obtained laminate. The evaluation results are shown in Table 2.

[0092] [Preparation of Laminate] After peeling off the protective layer from the thermosetting resin sheet, the thermosetting resin sheet was attached to a resin member at 23° C. using a roll laminator to prepare a laminate.

[0093] [Preparation of Molded Articles] (Examples 1 to 13) A laminate was vacuum-formed using a vacuum forming machine (manufactured by Asano Laboratory Co., Ltd., product name "FCS") under the molding conditions shown in Table 2 to produce a molded article. Thereafter, without removing the molded article from the mold, the molded article was further heat-treated in the vacuum forming machine under the curing temperature and curing time conditions shown in Table 2 while the mold was still pressed against the mold, to produce a molded article. The molded article thus produced had a car-shaped shape.

[0094] (Comparative Examples 1 and 2) A laminate was vacuum-formed using a vacuum forming machine (manufactured by Asano Laboratory Co., Ltd., product name "FCS") under the molding conditions shown in Table 2 to produce a molded product. The molded product produced had a car-shaped shape due to molding. Thereafter, before the thermosetting resin sheet cured, the molded product was removed from the mold, and the thermosetting resin sheet was cured using an oven (manufactured by Onsen Kibi Kenkyusho Co., Ltd., product name "Constant Temperature Drying Oven TEX Type") under the curing temperature and curing time conditions shown in Table 2 to produce a molded product.

[0095] *Table 1 shows the amount of each component in thermosetting resin compositions A and B based on solid content, with the total solid content of the acrylic polyol resin, plasticizing resin, and blocked isocyanate being 100 parts by mass. *The amount of active ingredient of the pigment is the value in Table 1 multiplied by 9 / 24.

[0096]

[0097] In the molded articles of Examples 1 to 13, the laminate was formed using a vacuum forming machine and the thermosetting resin sheet was cured, so the thermosetting resin sheet could be sufficiently cured in a short curing time without deforming the molded article. On the other hand, in Comparative Example 1, the thermosetting resin sheet was cured without using a vacuum forming machine, so when the curing temperature was increased in an attempt to sufficiently cure the thermosetting resin sheet in a short curing time, the molded article was deformed. Also, in Comparative Example 2, the thermosetting resin sheet was cured without using a vacuum forming machine, so when the curing temperature was lowered to prevent deformation of the molded article, the curing time required for the thermosetting resin sheet to be sufficiently cured was extended.

[0098] REFERENCE SIGNS LIST 1 thermosetting resin sheet 2 resin member 3 laminate 4 molded body 10 resin layer (paint layer) 11 resin layer (clear layer) 12 resin layer (colored layer) 20 transfer layer 30 protective layer 50 pressure roll 100 vacuum forming machine 110 molding die 120 heater 130 clamp

Claims

1. A method for producing a molded product, comprising: a first step of attaching a thermosetting resin sheet having a resin layer made of a thermosetting resin composition containing a curable resin to a resin member to produce a laminate; and a second step of molding the laminate using a vacuum molding machine to produce a molded product and curing the thermosetting resin sheet.

2. The method for producing a molded article according to claim 1, wherein in the second step, the thermosetting resin sheet is cured while the molded article is being produced.

3. A method for producing a molded body according to claim 1 or 2, comprising a third step of further promoting hardening of the thermosetting resin sheet in the produced molded body in the vacuum forming machine.

4. A method for producing a molded body as described in claim 3, wherein the third step further comprises using a heater of the vacuum forming machine to further promote hardening of the thermosetting resin sheet of the molded body while the forming mold of the vacuum forming machine is in contact with the resin member.

5. A method for producing a molded body, comprising: a first step of attaching a thermosetting resin sheet having a resin layer made of a thermosetting resin composition containing a curable resin to a resin member to produce a laminate; a fourth step of molding the laminate using a vacuum molding machine to produce a molded body; and a fifth step of curing the thermosetting resin sheet in the molded body inside the vacuum molding machine.

6. A method for manufacturing a molded body as described in claim 5, wherein the fifth step involves using a heater of the vacuum forming machine to harden the thermosetting resin sheet of the molded body while the forming mold of the vacuum forming machine is in contact with the resin member.

7. A method for producing a molded product according to any one of claims 1 to 4, wherein the thermosetting resin sheet further comprises a transfer layer on the side of the resin layer opposite to the side to which the resin member is attached.

8. The method for producing a molded product according to claim 7, wherein the transfer layer is peeled off from the thermosetting resin sheet before the second step.

9. The method for producing a molded article according to claim 7, wherein the transfer layer is peeled off from the thermosetting resin sheet after the second step.

10. A method for producing a molded body as described in claim 3 or 4, wherein the thermosetting resin sheet further comprises a transfer layer on the side of the resin layer opposite to the side to which the resin member is attached, and the transfer layer is peeled off from the thermosetting resin sheet after the third step.

11. The method for producing a molded body described in claim 5, wherein the thermosetting resin sheet further comprises a transfer layer on the side of the resin layer opposite to the side to which the resin member is attached, and the transfer layer is peeled off from the thermosetting resin sheet before the fourth step.

12. A method for producing a molded body as described in claim 5 or 6, wherein the thermosetting resin sheet further comprises a transfer layer on the side of the resin layer opposite to the side to which the resin member is attached, and the transfer layer is peeled off from the thermosetting resin sheet after the fifth step.

13. A method for producing a molded article according to any one of claims 7 to 12, wherein the transfer layer contains at least one resin selected from the group consisting of cycloolefin resin, vinyl chloride resin, polyester resin, polypropylene resin, and polyethylene resin.

14. A method for producing a molded body according to any one of claims 1 to 13, wherein the resin constituting the resin member is at least one resin selected from the group consisting of ABS (acrylonitrile-butadiene-styrene) resin, polypropylene resin, polyvinyl chloride resin, polyester resin and polycarbonate resin.

15. A method for producing a molded article according to any one of claims 1 to 14, wherein the thermosetting resin composition contains at least one compound selected from the group consisting of blocked isocyanates and melamine-based compounds.

16. The method for producing a molded article according to any one of claims 1 to 15, wherein the thermosetting resin composition contains a (meth)acrylic polyol.

17. The method for producing a molded article according to any one of claims 1 to 16, wherein the resin layer is a colored layer.

18. A laminate for molding with a vacuum molding machine, comprising a thermosetting resin sheet having a resin layer made of a thermosetting resin composition containing a curable resin attached to a resin member.

19. A vehicle equipped with a molded body manufactured by the method for manufacturing a molded body according to any one of claims 1 to 17.

20. A vehicle part comprising a molded body manufactured by the method for manufacturing a molded body according to any one of claims 1 to 17.

21. A method for manufacturing a vehicle, comprising the method for manufacturing a molded article according to any one of claims 1 to 17.

22. A method for producing a vehicle part, comprising the method for producing a molded body according to any one of claims 1 to 17.

23. A laminate used in the method for producing a molded article according to any one of claims 1 to 17.

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