THERMOSETTING RESIN MOLDED ARTICLE AND METHOD FOR PRODUCING SAME

• US 20160297127A1
• Filed: 11/04/2014
• Published: 10/13/2016
• Est. Priority Date: 12/19/2013
• Status: Abandoned Application

• Current Assignee: Proto Co., Ltd.
• Original Assignee: Proto Co., Ltd.
• Inventors: FURUYA, Tamio
• Application Number:
  US14/888,200
• Publication Number:
  US 20160297127A1
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: B05D 1/04 involving the use of an electrostatic field B05D1/025 and B05D1/14 take precedence
• CPC Class Codes: B05D 1/045 on non-conductive substrates
• CPC Class Codes: B29C 2037/0035 the coating being applied as liquid, gel, paste or the like
• CPC Class Codes: B29C 37/0032 the coating being applied upon the mould surface before introducing the moulding compound, e.g. applying a gelcoat B29C44/14 and B29C44/32 take precedence
• CPC Class Codes: B29C 45/1679 applying surface layers onto injection-moulded substrates inside the mould cavity, e.g. in-mould coating [IMC] applying suface layers after ejection B29C45/0053
• CPC Class Codes: B29C 67/246 Moulding high reactive monomers or prepolymers, e.g. by reaction injection moulding [RIM], liquid injection moulding [LIM] casting monomers B29C39/006, mixing construction B29B7/74
• CPC Class Codes: B29K 2055/02 ABS polymers, i.e. acrylonitrile-butadiene-styrene polymers
• CPC Class Codes: B29K 2075/00 Use of PU, i.e. polyureas or polyurethanes or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2507/04 Carbon
• CPC Class Codes: B29L 2009/006 painted
• CPC Class Codes: C23C 18/1641 Organic substrates, e.g. resin, plastic
• CPC Class Codes: C23C 18/1653 Two or more layers with at least one layer obtained by electroless plating and one layer obtained by electroplating
• CPC Class Codes: C23C 18/32 Coating with nickel, cobalt or mixtures thereof with phosphorus or boron C23C18/50 takes precedence
• CPC Class Codes: C25D 7/00 Electroplating characterised by the article coated

Abstract

Embodiments of the present invention provide a thermosetting resin molded article having a surface on which a plated membrane or a painted membrane may be formed without application of a mold release agent, defatting, sanding and primer processing. The thermosetting resin molded article is produced by a method of applying a thermoplastic resin solution obtained by dissolving at least a styrene resin in a solvent to at least a design forming area in a surface of a shaping mold; drying the shaping mold to form a thermoplastic resin membrane; and injecting a thermosetting resin composition into a cavity of the shaping mold and thermally curing the thermosetting resin composition, to obtain a thermosetting resin molded article having a surface on which the thermoplastic resin membrane. The thermoplastic resin solution may be obtained by dissolving the styrene resin and a carbon material in the solvent.

Claims

1. A method for producing a thermosetting resin molded article, the method comprising the steps of:

applying a thermoplastic resin solution obtained by dissolving at least a styrene resin in a solvent to at least a design forming area in a surface of a shaping mold;

drying the shaping mold to form a thermoplastic resin membrane; and

injecting a thermosetting resin composition into a cavity of the shaping mold and thermally curing the thermosetting resin composition, to obtain a thermosetting resin molded article having a surface on which the thermoplastic resin membrane,

wherein the styrene resin is a polystyrene, a styrene-acrylonitrile copolymerized resin (SAN resin), an acrylonitrile-butadiene-styrene copolymerized resin (ABS resin) or an acrylonitrile-ethylene-styrene copolymerized resin (AES resin), and wherein a temperature of the shaping mold is 40 to 80°

C.

3. The method for producing a thermosetting resin molded article according to claim 1, wherein the styrene resin is a plating-grade type ABS resin.

4. The method for producing a thermosetting resin molded article according to claim 3, further comprising:

non-electrolytically plating the surface of the thermosetting resin molded article.

5. The method for producing a thermosetting resin molded article according to claim 4, further comprising:

electrolytically plating the surface of the thermosetting resin molded article which is non-electrolytically plated.

6. The method for producing a thermosetting resin molded article according to claim 1, further comprising a step of painting the surface of the thermosetting resin molded article.

7. The method for producing a thermosetting resin molded article according to claim 1, wherein the thermoplastic resin solution is a solution obtained by dissolving the styrene resin and a carbon material in the solvent.

8. The method for producing a thermosetting resin molded article according to claim 7, wherein a resistance of the thermoplastic resin membrane is 1 to 500 kΩ

, wherein the thermoplastic resin membrane resistance is defined as a resistance between 1 cm in distance measured by a tester.

9. The method for producing a thermosetting resin molded article according to claim 7, further comprising a step of electroplating the surface of the thermosetting resin molded article.

10. The method for producing a thermosetting resin molded article according to claim 7, further comprising a step of electrostatically painting the surface of the thermosetting resin molded article.

11. The method for producing a thermosetting resin molded article according to claim 1, wherein non-electrolytic nickel-PTFE composite plating is conducted to at least the design forming area in the surface of the shaping mold.

12. The method for producing a thermosetting resin molded article according to claim 1, wherein the thermosetting resin composition is a urethane resin composition.

13. A thermosetting resin molded article produced by the method according to claim 1.

2. (canceled)