JP2001026026A - Manufacture of decorated gel-coat sheet and manufacture of molded product with gel-coat using the gel-coat sheet - Google Patents

Abstract

PROBLEM TO BE SOLVED: To obtain a durable molded product wherein a beautiful appearance can be maintained outdoors for a long period of time, which can not be developed by an SMC molded product, by a method wherein in molding by heating and pressurizing, a cured gel-coat sheet is inserted into a mold side, and molded simultaneously with a molding material. SOLUTION: A gel-coat wherein 100 pts. of gel-coat, 0.5 pts. of 6% cobalt naphthenate and 1.2 pts. of methyl ethyl ketone peroxide are blended is coated 0.2 mm in thickness on a mold of a glass plate. Then, after 5 min of a setting time, polyester nonwoven fabric of 50 g/m2 is placed and impregnated. Thereafter, it is placed to a curing furnace at 50 deg.C for 40 min, the gel-coat is cured, the cured gel-coat is cut in a required size, and a gel-coat sheet is obtained. The gel-coat sheet is placed at a set position of a bottom mold 3, an SMC sheet 2 is superimposed thereon, temperature of the bottom mold 3 is set at 145 deg.C, temperature of a top mold 4 is set at 135 deg.C, it is pressed by pressure of 60 kg/cm2 for several min, and a molded product with the gel-coat is obtained.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to FRP products such as bathroom units, vanity tables, wall panels, SMC, TMC, and the like.
The present invention also relates to a method for producing a gel coat sheet for the purpose of decorative protection and improvement of physical properties of the surface of a heat and pressure molded article such as BMC, and a method for producing a gel coat molded article using the gel coat sheet.

[0002]

2. Description of the Related Art Conventionally, methods for molding fiber reinforced plastic FRP products such as bathroom units, vanities, wall panels, etc., include hand lay-up using gel coat, spray-up, and FRP molding method using RTM.
The method is broadly classified into a press molding method in which a mold compound material such as SMC and BMC is heated and pressed with a mold.

A gel-coated FRP product intended to protect the decoration of the surface of the FRP product has an advantage because it can be freely patterned, but the hand lay-up molding method has a longer molding time than the press molding method. However, there is a disadvantage that the productivity is low and the production cost is high.

On the other hand, in the case of pressing methods such as SMC and BMC which are excellent in productivity, a molded article with a gel coat can be obtained by an in-mold coating method or the like, but a molded article having an excellent design can be obtained because only a single color gel coat can be used. Is difficult. In addition, since these molded articles contain a large amount of fillers such as calcium carbonate and aluminum hydroxide, they have poor weather resistance and cannot be used for applications that maintain their beautiful appearance outdoors for a long time.

Japanese Patent Application Laid-Open No. Hei 5-318468 discloses a method for producing a molded article with a gel coat, in which a gel coat sheet is produced by setting a gel coat in a semi-cured state, and the gel coat sheet is overlaid with a molding material and heated and pressed. Has been described. However, since the gel coat sheet is in a semi-cured state, the coloring component of the gel coat layer and the patterned pattern are eluted by the monomer component of the molding material at the time of molding, or flow into the end face. In addition, there is a defect that cracks occur at the emboss and joint portions, and the molding material seeps out therefrom.

In addition, since it is in a semi-cured state, it is difficult to adjust the degree of curing, and if the degree of curing is insufficient, the colorant and the patterned pattern due to the monomer component of the molding material are largely eluted, and the flow at the end face is likely to occur. Become. Further, there is a disadvantage that cracks occur when the degree of curing is excessive. There is a drawback that a gel coat sheet in a semi-cured state cannot be piled up during transfer.

On the other hand, Japanese Patent Application Laid-Open No. Hei 8-177482 discloses that a pattern layer is formed by patterning one side of a sheet by gel coating, a blocking mat is laminated on the pattern layer, and a patterning sheet is set on a mold surface. A production method is described in which a molding material is stacked and molded to form a patterned molded product. However, as in JP-A-5-318468,
The use of a semi-cured gel coat makes it difficult to adjust the degree of cure, and if the degree of cure is insufficient, the colorant and the patterned pattern due to the monomer component of the molding material are largely eluted, and the flow at the end face is likely to occur. . Further, there is a disadvantage that cracks occur when the degree of curing is excessive.

Also, cracks occur at the embossed joints,
Although it is reinforced with a shielding mat to prevent the molding material from seeping out from it, there is a disadvantage that the cost is high because the gel coat is in a semi-cured state and a thick one must be used for the shielding mat. .

As a method for producing a patterned FRP molded product, Japanese Patent Publication No. 2530105 (Japanese Patent Laid-Open No.
No. 60) discloses a method in which a melamine resin is impregnated into titanium paper having a desired pattern and color, and melamine powder is evenly sprinkled on the surface of the melamine resin and dried. To obtain a molded article with a pattern. However, only a molded product having a flat shape or a mold shape of 10 to 20 mm can be patterned. In addition, a method is generally used in which a non-woven fabric decorated with printing or the like and titanium paper impregnated with a DAP resin or a polyester resin are placed on a mold side, and a molding material is stacked thereon and molded. But also a plane or 1
Only a molded article having a shape of 0 to 20 mm can be patterned. Similarly, in the methods described in JP-A-5-318468 and JP-A-8-174782, only a molded product having a flat surface or a mold shape of 10 to 20 mm can be patterned.

Japanese Patent Publication Nos. 58-45938 and 58-45939 disclose a method of manufacturing a molded article with a reinforced plastic pattern, in which a patterned cloth is sewn to a bathtub and sewn with a bag. A method is described in which a molding material is overlaid and molded over a mold after curing. However, the bag sewing process is complicated and costly, and the patterned layer forms the product surface, so that only a molded product without flat depth and poor design can be obtained.

[0011]

DISCLOSURE OF THE INVENTION In view of the above-mentioned prior art, the present invention provides a method for dissolving a colorant at the time of molding due to a gel coating sheet being in a semi-cured state, a flow of a patterned handle,
An object of the present invention is to make it possible to easily obtain a molded article with a gel coat by developing a decorative gel coat sheet which does not generate a flow on an end face and does not generate a crack at an emboss or joint. In addition, because there was only a decorative sheet having a flat shape in the past, a molded article decorated with a free-form pattern could not be obtained, but the present invention makes it possible to obtain a decorative molded article having a free shape. It is to be.

Furthermore, the gel coat used in the present invention has extremely high weather resistance as compared with the conventional unsaturated polyester resin gel coat used on the surface of FRP, so that it could not be developed with an SMC molded product, It is an object of the present invention to obtain a molded article that can withstand applications that maintain its appearance for a long time.

[0013]

That is, the present invention relates to a method for producing a gel-coated product by inserting a molding material into a mold at the time of heat and pressure molding and molding the same with a molding material. The method for producing a cured gel coat sheet according to claim 1, wherein the cured gel coat sheet is a flat mold, a mold having a free shape, a film, or a release mold. A method for producing a gel coat sheet obtained by spraying or coating a thermosetting resin gel coat to which a curing agent has been previously added to a paper pattern and curing the gel paper (claim 2), wherein the gel coat sheet is a modified acrylic resin composition The method for producing a gel coat sheet according to claim 1 or 2, wherein the cured gel coat sheet is a woven fabric, The method for producing a gel coat sheet according to claim 1 or 2, wherein the gel coat sheet is transparent or translucent, and is woven on a back surface thereof. The method for producing a gel coat sheet according to claim 2, which has a decorative pattern obtained by bonding at least one of cloth, nonwoven fabric, and paper (claim 5), and decorating the back surface of the gel coat sheet. The method for producing a gel coat sheet according to claim 5, wherein the gel coat sheet is decorated by printing or ink jet (Claim 6), wherein the gel coat sheet is transparent or translucent, and the back surface is decorated. The method for producing a gel coat sheet according to claim 2, wherein the back surface has a decorative pattern (claim 7), and the decoration on the back surface of the gel coat sheet is performed by direct printing. The method for producing a gel coat sheet according to claim 7, which is a decoration (claim 8),
After the gel coat sheet is cured, it is inserted into the mold side, and when heated and pressed at the same time as the molding material, it has the flexibility to follow the mold shape and not to cause cracks or breakage, and Claims 2 and 3 comprising a composition having excellent adhesion.
The method for producing a gel coat sheet according to 4, 5, 6, 7 or 8 (Claim 9), and cutting the gel coat sheet according to the shape of a place to be decorated, inserting the gel coat sheet into a predetermined position of a mold, and forming a molding material. And a method for producing a molded article with a gel coat according to claim 1, wherein the molded article is molded simultaneously.

[0014]

BEST MODE FOR CARRYING OUT THE INVENTION The present invention relates to a method in which a flat glass plate, a metal plate such as stainless steel, or a thermosetting resin gel coat obtained by adding a curing agent in advance to a base film is applied by spraying or doctor coating. The present invention relates to a method for producing a decorative gel coat sheet obtained by reinforcing with glass, titanium paper, woven or nonwoven fabric of organic fiber or inorganic fiber or paper, and after impregnation and curing.

In addition to the above, a thermosetting resin gel coat obtained by adding a curing agent in advance to a free-form FRP mold or a mold is applied by spraying or brushing, and if necessary, glass, titanium paper, organic The present invention relates to a method for producing a decorative gel coat sheet obtained by reinforcing with a woven or non-woven fabric of fibers or inorganic fibers or paper, impregnating and curing.

The manufacturing method of the present invention is characterized in that a cured gel coat is used. In the prior art, the combination of α-methylstyrene dimer, etc.,
Two-stage curing is performed in which a so-called semi-cured state having a low crosslinking density is obtained and completely cured during high-temperature press molding.
The cured gel coat in the present invention refers to a gel coat that is completely cured at an appropriate temperature of a curing agent to be used, and can be quantitatively confirmed by hardness measurement or residual styrene amount measurement.

As a method for industrial continuous production of the acrylic resin gel coat sheet according to the present invention, the acrylic resin gel coat according to the present invention is applied between two continuous films, and then, if necessary, titanium paper is applied. It is also possible to obtain a continuous gel coat sheet by reinforcing with a non-woven fabric or glass paper and passing through an impregnation process.

The base film used in the present invention is not particularly limited as long as it has a heat-resistant peeling property and is insoluble in a gel coat resin component, but it may be a plastic film such as polyethylene, nylon, polyester, or fluororesin, or an aluminum foil. Such a material is used in which a metal such as such is adhered to a simple substance or another film, or a material in which a resin having releasability is applied to the surface of paper or a plastic film is used. There is no particular limitation on the thickness, but if the thickness is 20 μm or less, when the coated gel coat is cured, wrinkles and warpages occur and handling becomes inconvenient, and if it is 100 μm or more, the cost increases. Preferably, the thickness is 20 to 100 μm.

When a mold having a free shape is used, the mold can be freely used as long as the gel coat sheet can be peeled off after the curing treatment. As the material of the mold, a plastic mold or a metal mold can be used freely. The mold is used after being subjected to mold release treatment with wax (such as miragrace) or a liquid mold release agent (such as Flicoat or Chemrease). In some cases, the mold release treatment can be omitted by adding an internal mold release agent (such as Moldwiz INC-BQ6) to the gel coat in advance.

The method of applying a gel coat to a mold or a base film includes a method of applying by spraying or brushing with a spray gun or a multi-color pattern spraying device (JP-A-4-330956), There is a coating method using a roll coater, a doctor coater, an air knife coater, or the like.

The thickness of the coating is 0.1 to 2.0 mm.
When it is 0.3 mm or less, it tends to break when it is released from the mold and peeled off as a gel coat sheet, and when it is 1 mm or more, the cost tends to be high. Therefore,
It is desirable to apply with a thickness of 0.3 mm to 1.0 mm. In particular, when a gel coat made of an acrylic resin is applied, if the thickness of the coat is 0.3 mm or less, there is a disadvantage that a high gloss appearance, which is a characteristic of an acrylic resin molded product, cannot be obtained well. It is preferable to apply with a thickness of 3 mm or more.

The gel coat may be applied once, but may be applied twice or more. In that case, a transparent or translucent gel coat is applied to the surface, and a second color gel coat, multi-color pattern gel coat, granite gel coat (filler gel coat such as stone filler),
By applying the pearly gel coat repeatedly, it is possible to obtain a product having a deep feeling and excellent in design.

In the case of decorating the back surface, it is possible to apply only a transparent or translucent gel coat layer.

The gel coat sheet can be used without reinforcement. However, in order to improve the followability to the shape of the mold, it is necessary to use a reinforcement sheet made of at least one of woven fabric, non-woven fabric and paper made of organic fibers or inorganic fibers. Can be. The thickness of the woven fabric, nonwoven fabric or paper used as the reinforcing sheet is not particularly limited, but is 10 to 60 g / m ² because it has excellent gel coat impregnation and can prevent crack rupture due to the shape of the mold during molding. It is preferable to use

As the woven fabric, nonwoven fabric or paper used as the reinforcing sheet, those which have been decorated in advance by printing or ink jet can be used.

At least one of a woven fabric, a nonwoven fabric, and a paper of an organic fiber or an inorganic fiber decorated on the back surface of a transparent or translucent gel coat sheet by printing or ink jet or the like.
There is no particular limitation on the thickness and the material of the material used when the seeds are stacked and molded, as long as they do not prevent impregnation of the SMC and BMC compound materials at the time of molding.

The back surface of the transparent or translucent gel coat sheet can be directly decorated by screen printing or ink jet. The ink used is decorated with an ink that does not elute with the monomer component of the molding material after curing, such as a curable acrylic urethane resin ink.

As a component of the thermosetting resin gel coat, an acrylic resin, an unsaturated polyester resin, a diallyl phthalate resin (DAP resin) or the like can be used, and an acrylic resin having a heat deformation temperature of 65 to 120 ° C. is used in an amount of 20 to 100% by weight.
By containing it, a gel coat sheet that follows a mold shape without cracks, breaks, and the like at the time of heat and pressure molding after curing treatment can be obtained. Further, as the acrylic resin, a modified acrylic resin using a type using a resin composed of an acrylic polymer and an acrylic monomer and using an organic peroxide as a curing agent is preferable. Further, as the unsaturated polyester resin, a resin having excellent heat resistance such as a vinyl ester type, an isophthalic acid type, and a bisphenol type unsaturated polyester resin can be used, but an orthophthalic acid type resin can be used depending on the application. .

The acrylic monomer used in the modified acrylic resin includes (meth) acrylic acid derivatives exemplified below.

(A) Monofunctional (meth) acrylates: methyl (meth) acrylate, ethyl (meth) acrylate, isopropyl (meth) acrylate, hydroxyethyl (meth) acrylate, tetrahydrofurfuryl (meth) acrylate, Glycidyl (meth) acrylate, p- (meth) acryloxybenzoic acid, benzyl (meth) acrylate, butoxyethyl (meth) acrylate, butoxytriethylene glycol (meth) acrylate, 3-chloro-2-hydroxypropyl (meth) acrylate, Cyclohexyl (meth) acrylate, dicyclopentanyl (meth) acrylate, N, N
-Dimethylamino (meth) acrylate, ethyldiethylene glycol (meth) acrylate, 2-ethylhexyl (meth) acrylate, glycerol (meth) acrylate, heptadecafluorodecyl (meth) acrylate, isobornyl (meth) acrylate, lauryl (meth) acrylate, 3-phenoxy-2-hydroxypropyl (meth) acrylate and the like.

(B) Polyfunctional (meth) acrylates: propanediol di (meth) acrylate, butanediol di (meth) acrylate, decanediol di (meth) acrylate, ethylene glycol di (meth) acrylate
Acrylate, diethylene glycol di (meth) acrylate, propylene glycol di (meth) acrylate, dipropylene glycol di (meth) acrylate,
Glycerin di (meth) acrylate, bisphenol-
A di (meth) acrylate, 2,2-di (4- (meth)
(Acryloxypolyethoxyphenyl) propane, trimethylolpropane tri (meth) acrylate, pentaerythritol tri (meth) acrylate, tris (meth) acryloxyethyl isocyanurate, dipentaerythritol hexa (meth) acrylate, and the like.

(D) Urethane (meth) acrylates:
2-hydroxypropyl (meth) acrylate, 2-
Diadduct obtained by an addition reaction of a hydroxyl group-containing (meth) acrylate such as hydroxyethyl (meth) acrylate with a diisocyanate such as hexamethylene diisocyanate or diisocyanate methylbenzene.

In addition to these, known and commercially available products for industrial use may be used, and these compounds may be used alone or in combination of two or more depending on the purpose.

As a curing agent, methyl ethyl ketone peroxide (MEKPO), benzoyl peroxide (BPO), carbonate peroxide and other organic peroxides are used. If necessary, an accelerator such as cobalt naphthenate is used in combination as an initiator for the copolymerization reaction. The amount of the curing agent used may be determined depending on the desired curing speed, curing temperature, mechanical strength of the cured product, etc., and is not particularly limited. It is preferably from 5.0 to 5.0 parts by weight. If the amount is more than 5.0 parts by weight, the curing may proceed rapidly to cause foaming or cracking. If the amount is less than 0.1 parts by weight, the curing tends to be insufficient.

The elongation percentage of such an acrylic resin is 5%
It is preferable that it is above. If it is less than 5%, cracks and cracks tend to occur during press molding. Tg is 40 ~
It is preferably 130 ° C. If the temperature exceeds 130 ° C., cracks and cracks occur during press molding, and if it is lower than 40 ° C., the water resistance of the molded product tends to decrease.

The curing treatment can be carried out at room temperature by a combination of the above-mentioned curing agent and accelerator.
40-60 ° C x 20 for a cobalt naphthenate-based curing system
~ 60 minutes, 60 ~ 8 for carbonate peroxide system
It is preferable to perform a curing treatment at 0 ° C. × 20 to 60 minutes.

The liquid viscosity of the gel coat is 3-50 at 25 ° C.
Poise, thixotropic 1-6.5. Therefore, it is preferable to add 0 to 5 parts of silica. To adjust the viscosity, 0 to 45% by weight of a monomer such as MMA (methyl methacrylate) 2-ethylhexyl and a styrene monomer is added.

As the coloring agent, pigments having excellent heat resistance and weather resistance, such as titanium oxide, carbon black, iron oxide yellow, red iron oxide, isoindolinone yellow, naphthol red, phthalocyanine blue, phthalocyanine green, cobalt blue, and sinkasha red. It is used in an amount of 0.1 to 20% by weight, preferably 0.1 to 15.0% by weight. If necessary, 0 to 20% by weight of a moisture-resistant pigment such as calcium carbonate, talc or aluminum hydroxide is used. The gel coat sheet of the granite pattern (stone pattern) uses 0.1 to 20% by weight of a filler such as a mica surface-coated one, a cut plastic film, or a cut organic fiber.
For pearly gel coat sheet, pearl pigment 0.1 ~
Use 20% by weight. The pigments, fillers and pearl pigments can be used arbitrarily.

The gel coat sheet prepared as described above is placed on the whole or at a desired position of the mold, and SMC,
The molding materials such as BMC and TMC are stacked and molded under heat and pressure. Cutter knife to get the desired size and shape,
Cut with scissors or Thomson die cutting.

[0040]

EXAMPLES Examples of gel coat formulations and materials used are shown below. Unless indicated otherwise, parts are parts by weight.

Gel coat 1 75.0 parts of acrylic resin, unsaturated polyester resin 1
0.0 parts, 3.0 parts of silica, 0.5 parts of defoamer, MMA
4.0 parts, titanium oxide 6.9 parts, isoindolinone yellow 0.5 parts and carbon black 0.1 parts (total 1 part)
00.0 parts)

Gel coat 2 75.0 parts of acrylic resin, unsaturated polyester resin 1
0.0 parts, 3.0 parts of silica, 0.5 parts of defoamer, MMA
4.0 parts, titanium oxide 6.5 parts, carbon black 2.
0 parts (total 100.0 parts)

Gel coat 3 50.0 parts of acrylic resin, unsaturated polyester resin 2
5.0 parts, silica 3.0 parts, defoamer 0.5 parts, MMA
4.0 parts, styrene monomer 10.0 parts, titanium oxide 7.0 parts, phthalocyanine blue 0.5 parts (total 10 parts)
0.0 parts)

Gel coat 4 52.5 parts of acrylic resin, unsaturated polyester resin 2
5.0 parts, silica 3.0 parts, defoamer 0.5 parts, MMA
4.0 parts, styrene monomer 10.0 parts, pearl pigment 5.0 parts (total 100.0 parts)

Gel coat 5 91.0 parts of acrylic resin, 3.5 parts of silica, 0.
5 parts, MMA 5.0 parts (100.0 parts)

Gel coat 6 Acrylic resin 52.5 parts, unsaturated polyester resin 2
5.0 parts, silica 3.0 parts, defoamer 0.5 parts, MMA
4.0 parts, styrene monomer 10.0 parts, mica flakes 5.0 parts (total 100.0 parts)

Gelcoat 7 75.0 parts of modified acrylic resin, 3.0 parts of silica, 0.7 parts of defoamer, 21.3 parts of MMA (total 100.0 parts)

Gelcoat 8 75.5 parts of modified acrylic resin, 3.0 parts of silica, 0.7 parts of defoamer, 15.8 parts of MMA, 5.0 parts of titanium oxide (total of 100.0 parts)

Gelcoat 9 75.0 parts of modified acrylic resin, 3.0 parts of silica, 0.7 parts of defoamer, 16.3 parts of MMA, 5.0 parts of pearl pigment (total of 100.0 parts)

Gelcoat 10 75.0 parts of modified acrylic resin, 3.0 parts of silica, 0.7 parts of defoamer, 16.3 parts of MMA, 5.0 parts of mica flake
(100.0 parts in total)

Acrylic resin: ICI Japan K.K./Modal GC-701I Modified acrylic resin: ICI Japan K.K./Modal AGS-100 Unsaturated polyester resin: Nippon Yupika Co., Ltd./Yupika 6505, 6400 Dainippon Ink and Chemicals, Inc. Manufacture / Polylite FG-283, 586 Takeda Pharmaceutical Co., Ltd./Polymer 6330F Titanium oxide: Dupont Co., Ltd./R-900 Ishihara Sangyo Co., Ltd./CR-85 Isoindoline Yellow: Ciba Specialty Chemicals Co., Ltd./Irgazine Yellow 2GLTE Shinkasha Red: Ciba Specialty / Shinkasha Red Y. RT-759D Phthalocyanine blue: DAINICHI SEIKA KOGYO CO., LTD./4950 Carbon black: Degussa / Special Black # 4 Pearl pigment: Merck Japan Co., Ltd./Iriodin 163 Shima Pearl Mica Flake: DIA KOGYO Co., Ltd./Diachip

Example 1 Gelcoat 1 100 parts, 6% cobalt naphthenate 0.1%
A gel coat containing 5 parts and 1.2 parts of MEKPO was applied to a glass plate mold at a thickness of 0.5 mm with an Iwatani / cup gun. After a setting time of 5 minutes, 50 g / m ² of a polyester nonwoven fabric was placed and impregnated. Thereafter, the gel coat was cured by placing it in a curing oven at 50 ° C. for 40 minutes. It was taken out of the curing furnace and peeled off from the mold after 30 minutes. The obtained gel coat sheet was cut into a desired size and shape by a cutter. The obtained gel coat sheet 1 is placed at a predetermined position of the lower mold 3, and the SMC sheet 2 is placed thereon.
Were pressed at a pressure of 60 kg / cm ² for 10 minutes while setting the temperature of the lower mold 3 at 145 ° C. and the temperature of the upper mold 4 at 135 ° C. The molded article 5 obtained after demolding is a molded article with a gel coat having the gel coat layer 1.

Example 2 Mixture of 0.5% of 6% cobalt naphthenate was previously mixed with Gelcoat 1 (ivory color), Gelcoat 2 (Gray color) and Gelcoat 4 (Pearl color), followed by stirring. Pumping tanks 6, 7,
8 and FRP type 9 and multicolor gel coat spray device 10
Was spray-coated to a thickness of 0.3 to 0.5 mm. The amount of the curing agent at that time is 1 to 1.
The curing agent tank 11 was set so as to have 5 parts. After a setting time of 5 minutes, the gel coat was cured by placing it in a curing oven at 50 ° C. for 30 minutes. After taking out from the curing furnace, the cock is opened only in the pressure-feeding tank 6 after 30 minutes, and the curing agent tank 1 is placed on the cured multicolored gel coat layer 12 so that the curing agent is also 1.0 to 1.5 parts with respect to the gel coat.
Gel coat layer 1 having a thickness of 0.1 to 0.3 mm set to 1
I made 3. Immediately after coating, 5
According to the shape of the mold, it was impregnated with an impregnating roller so as to have 0 g / m ² .

Thereafter, the gel coat layer was cured by placing it in a curing oven at 50 ° C. for 30 minutes. 3 after removal from curing oven
After standing for 0 minutes, the mold was gently removed from the mold. The multicolored gel coat sheet 15 having the obtained shape is placed on the lower mold 16 according to the mold, and the SMC sheet 2 is superimposed thereon, and the lower mold 1
The temperature of No. 6 was set to 150 ° C., the temperature of the upper mold 17 was set to 140 ° C., and pressing was performed at a pressure of 100 kg / cm ² for 10 minutes.
The molded product 18 obtained after demolding was a molded product with a gel coat, which was decorated in various colors on the entire surface of the molded product.

Example 3 A gel coat comprising 100 parts of gel coat 7, 0.5 parts of 6% cobalt naphthenate and 1.2 parts of MEKPO was applied to a 50 μm-thick PET film placed on a glass plate using a bar coater. Then, a titanium paper on which a pattern was printed was placed, and the gel coat was further applied thereon.
A 50-μm-thick PET film is covered thereover, impregnated with a roller, placed on a glass plate, and placed at room temperature for 1 hour.
Left for hours. Thereafter, the gel coat was cured by placing it in a curing oven at 50 ° C. for 1 hour. The resulting gel coat sheet 1 is cut into a desired size and shape, and the obtained gel coat sheet 1 is placed at a predetermined position on the lower mold 3, and the SMC sheet 2 is stacked thereon, and the temperature of the lower mold 3 is raised to 150 ° C. The temperature of the mold 4 was set to 135 ° C., and pressing was performed at a pressure of 100 kg / cm ² for 7 minutes. The molded article 5 obtained after demolding was a gel-coated article having the gel coat layer 1.

Example 4 A gel coat obtained by mixing 100 parts of gel coat 8, 0.5 parts of 6% cobalt naphthenate and 1.2 parts of MEKPO was applied to a 50 μm thick PET film placed on a glass plate using a bar coater. And put glass paper for reinforcement, after impregnation to some extent, thickness of 50μm from above
PET film. Then, the glass plate was put and left at room temperature for 1 hour. Thereafter, the gel coat was cured by placing it in a curing oven at 50 ° C. for 1 hour. Desired size
The gel coat sheet 1 is cut into a shape, and the obtained gel coat sheet 1 is placed at a predetermined position of the lower mold 3, the SMC sheet 2 is stacked thereon, the temperature of the lower mold 3 is set to 150 ° C., and the temperature of the upper mold 4 is reduced. Temperature 1
It was set at 35 ° C. and pressed at a pressure of 100 kg / cm ² for 7 minutes. The molded article 5 obtained after demolding was a gel-coated article having the gel coat layer 1.

Comparative Example 1 Gelcoat 8 100 parts, bis (4-t-butylcyclohexyl) peroxydicarbonate (manufactured by Kayaku Akzo)
Parkadox 16) A gel coat containing 1 part was applied to a glass plate mold with a Iwatani / cup gun to a thickness of 0.5 mm. Then, it was heated in a curing oven at 50 ° C. for 30 minutes.

It was taken out of the curing furnace and peeled from the mold.
The obtained gel coat sheet had a tack on the surface and was in a semi-cured state having elasticity. This gel coat sheet is cut into a desired size by a cutter (gel coat sheet 1), placed at a predetermined position on the mold 3, and the SMC sheet 2 is placed thereon, and the temperature of the lower mold 3 is raised to 145 ° C. Mold 4
At 135 ° C. and a pressure of 60 kg / cm ² for 10
Pressed for minutes. After demolding, the resulting molded article had low gloss on the gel coat surface, cracked, and the molding material on the back was exposed.

The cured product of the gel-coated product obtained in Examples 1 to 4 and Comparative Example 1 was irradiated with 50 J / cm ² of ultraviolet light using a high-pressure mercury lamp to evaluate the weather resistance. As a result, no gloss deterioration or color change on the UV-irradiated surface was observed.

[0060]

According to the production method of the present invention, since the cured gel coat sheet is used, the dissolution of the coloring agent during molding,
There is no flow of the patterned pattern, flow of the end face, etc.
A molded article with gel coat can be easily obtained, and when inserted into the mold side and heated and pressed simultaneously with the molding material, it has the flexibility to follow the mold shape and prevent cracks and breakage, and Excellent adhesion to materials. Also, by using a gel coat made of a modified acrylic resin, it has extremely excellent hot water resistance, weather resistance and chemical resistance as compared with the gel coat used on the conventional FRP surface, so it cannot be developed with an SMC molded product. In addition, it is possible to obtain a molded article that can be used for maintaining the aesthetic appearance outdoors for a long period of time.

[Brief description of the drawings]

FIG. 1 is an explanatory view showing a method for producing a molded article with a gel coat sheet using the gel coat sheet of the present invention.

FIG. 2 is a cross-sectional view of a molded article obtained by the manufacturing method shown in FIG.

FIG. 3 is an explanatory view showing a method for producing a gel coat sheet used in the present invention.

FIG. 4 is an explanatory view showing a method for producing a gel coat sheet used in the present invention.

FIG. 5 is an explanatory view showing a method for producing a molded article with a gel coat sheet using the gel coat sheet of the present invention.

FIG. 6 is a cross-sectional view of a molded product obtained by the manufacturing method shown in FIG.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Gel coat sheet 2 SMC sheet 3 Lower mold 4 Upper mold 5 Molded product 6 Pressure tank 1 7 Pressure tank 2 8 Pressure tank 3 9 FRP type 10 Multicolor gel coat spray device 11 Curing agent tank 12 Multilayer gel coat layer 13 Gel coat Layer 14 Polyester nonwoven fabric 15 Multicolor gel coat sheet 16 Lower mold 17 Upper mold 18 Molded product

Continuing from the front page (72) Inventor Sanshi Nakamura 101 Kokubunji, Ogunino-cho, Himeji-shi, Hyogo AC03 AD05 AD06 AD09 AD11 AD16 AD19 AD27 AG03 HA08 HA25 HA33 HA35 HA44 HB01 HB11 HC05 HC06 HC08 HC13 HE06 HE16 HE21 HF01 HF05 HF23 HF24 HF25 HK02 HK03 HK04 HK05 HK16 HT04 HT13 HT27

Claims (10)

[Claims] 1. A method for producing a gel-coated product, which is inserted into a mold during heat-press molding and molded simultaneously with a molding material, wherein a cured gel coat sheet is used. 2. The method for producing a cured gel coat sheet according to claim 1, wherein the cured gel coat sheet comprises:
A method for producing a gel coat sheet obtained by spraying or coating a thermosetting resin gel coat to which a curing agent has been added in advance on a flat mold, a mold having a free shape, a film or release paper, followed by a curing treatment. 3. The method for producing a gel coat sheet according to claim 1, wherein the gel coat sheet is a gel coat comprising a modified acrylic resin composition. 4. The method for producing a gel coat sheet according to claim 1, wherein the cured gel coat sheet is reinforced with at least one of woven fabric, non-woven fabric and paper. 5. The gel coat sheet is transparent or translucent, and has a decorative pattern obtained by bonding at least one of decorative woven fabric, non-woven fabric, and paper on the back surface thereof. 5. The method for producing a gel coat sheet according to item 4. 6. The method for producing a gel coat sheet according to claim 5, wherein the decoration on the back surface of the gel coat sheet is decoration by printing or ink jet. 7. The gel coat according to claim 2, wherein the gel coat sheet is transparent or translucent and has a decorative pattern on the back surface thereof. Sheet manufacturing method. 8. The method for producing a gel coat sheet according to claim 7, wherein the decoration on the back surface of the gel coat sheet is decoration by direct printing. 9. When the gel coat sheet is cured and heat-pressed simultaneously with the molding material after being inserted into the mold side, the gel coat sheet has flexibility so that it does not crack or break following the mold shape, The method for producing a gel coat sheet according to claim 2, wherein the composition has a composition excellent in adhesion to a molding material. 10. A gel coat sheet is cut in accordance with the shape of a place to be decorated and inserted into a predetermined position of a molding die.
The method for producing a molded article with a gel coat according to claim 1, wherein the molding materials are overlapped and molded at the same time.