JP2002219775A - Frp molding - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide FRP moldings with a specified pattern which can be stably obtained by following up irregularities faithfully and securely keep a perfect linearity in the borderline of the pattern and shows outstanding various performances at a low cost. SOLUTION: The FRP moldings are obtained by laminating a thermally curable transparent resin film or sheet with a previously imparted specified design and an FRP molding material and thermally molding the laminate under pressure. The FRP molding material is composed of a sheet molding compound or a bulk molding compound. The thermally curable transparent resin film or sheet has a specified design imparted by printing and has an air bleeder hole.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an FRP molded article used for a waterproof pan of a unit bath, for example.

[0002]

2. Description of the Related Art Conventionally, as FRP molded articles such as waterproof pans, for example, Japanese Patent Application Laid-Open Nos.
JP-A-300381, JP-A-11-254470, JP-A-11-2680065 and JP-A-11-268
No. 207878. First, Japanese Patent Application Laid-Open
-FRP molded article (molded article A)
Is a method of impregnating a resin such as DAT (diallyl phthalate) into a titanium paper having a pattern made of cellulose and titanium oxide to form a prepreg sheet, which is pressed and heated simultaneously with a sheet molding compound (SMC). It was done.

Further, a FRP molded article (referred to as molded article B) disclosed in Japanese Patent Application Laid-Open No. 8-300381 is formed by molding a transfer paper formed by printing a pattern on a heat-resistant film by applying pressure and heating simultaneously with SMC. After that, the heat-resistant film was peeled off to form a transparent thermosetting resin layer on the surface of the molded product by curing. Further, the FRP molded article (referred to as molded article C) disclosed in Japanese Patent Application Laid-Open No. H11-254470 was formed by superimposing a decorative material having a pattern surface on SMC, pasting them together by a preliminary press bonding machine, and then press-molding. Things.

[0004] Further, an FRP molded article (referred to as molded article D) disclosed in Japanese Patent Application Laid-Open No. 11-268065 integrates a printed polyester nonwoven fabric and a plain polyester nonwoven fabric by heat welding, and forms a thermosetting resin. A prepreg sheet is formed by impregnating a resin, and this prepreg sheet and SMC are molded simultaneously. Also, Japanese Patent Application Laid-Open
No. -207878 discloses an FRP molded product (molded product E).
Is a method in which a decorative molding sheet obtained by applying a thermosetting resin as a binder to a decorated base film and an SMC or the like are laminated and heat molded.

[0005]

However, in the molded body A, since titanium paper having high paper quality is used,
When water enters the molded body due to poor impregnation of the resin into the titanium paper or cracks in the titanium paper itself, mold is generated in the portion, and when used in a molded body such as a waterproof pan, the cleanliness is reduced. In addition to having the problem, the titanium paper itself does not stretch, so in the case of a molded product having large irregularities, the titanium paper cannot follow the irregular shape, torn, and the molded article is likely to be defective. are doing.

In the molded article B, since the transparent resin is applied, for example, by spray coating after the heat-resistant film is peeled off, the surface of the molded article becomes relatively gentle, and when the molded article is a waterproof pan, In addition to the problem that the bather easily slips, when the paint is applied by using the preheating after removal from the mold, the solvent in the paint rapidly evaporates, and the work environment is easily deteriorated. I have. Further, in the case of the molded body C, since two steps of a bonding step using a pre-compression bonding machine and a normal molding step are required, the molding cycle length is increased, and the production cost of the molded body is likely to be increased. Has problems.

Further, in the molded article D, the printed polyester non-woven fabric and the plain polyester non-woven fabric are converted to SM
When the SMC is flowed on a mold at 130 to 150 ° C. to heat and mold simultaneously with C, there is a problem that the softened polyester nonwoven fabric is deformed due to the flow resistance, and defective molding is likely to occur. I have. In this regard, when an experiment was performed using a waterproof pan 100 as shown in FIG. 6, for example, the left and right cut lines (referred to as boundary lines L) and the like of the waterproof pan 100 were about l = 5 mm in the center of the egg. It has been confirmed that the boundary line L is liable to be disturbed, such as swelling in the shape of a waterproof pan.
It is difficult to apply to a waterproof pan 100 having a smooth surface with no pattern on a.

In the case of the molded article E, a thermosetting resin as a binder is applied to a base film, laminated with an SMC or the like, and press-molded, so that the applied state of the thermosetting resin varies. Therefore, the adhesion strength between the base film and the SMC tends to vary, and it is difficult to obtain a stable molded body. In addition, since the base film does not allow air to pass through, the SMC and the base film are not allowed to pass through. In addition, there is a problem that molding defects are apt to occur due to the air pool between them.

[0009] The applicant of the present invention has proposed a FRP molded article which solves such a problem as disclosed in Japanese Patent Application No. 2000-182.
No. 9 was filed. As shown in FIG. 7, this FRP molded article is prepared by impregnating a thermosetting composition into an organic fiber-based nonwoven fabric containing no cellulose component and having a predetermined pattern formed in advance, to prepare a prepreg sheet 101, 10
SMC 103 and the like are laminated on the base material 1 via a heat-resistant fiber reinforcing material 102, and the laminated body 104 is divided into upper and lower molds 105 and 106.
And pressurized and heated.

According to this FRP molded body, the mold 105,
It is possible to obtain a stable molded body that follows the uneven shape of 106, to form a stable pattern at low cost, and to clearly define the boundary L of the pattern. However, since the heat resistance temperature of the non-woven fabric of the prepreg sheet 101 is lower than the molding temperature in subsequent experiments, the non-woven fabric is deformed at the molding temperature, and it is difficult to stably secure sufficient linearity at the boundary L of the pattern. The problem became clear.

SUMMARY OF THE INVENTION The present invention has been made in view of such circumstances, and an object of the invention described in claim 1 or 2 is to provide a molded article having a predetermined pattern stably following an uneven shape. Another object of the present invention is to provide an inexpensive FRP molded body which has sufficient linearity at the boundary of the pattern, and is excellent in various performances. The object of the invention described in claim 3 is:
In addition to the object of the invention described in claim 1 or 2, there is provided an FRP molded article which can be formed at a lower cost by stably imparting a predetermined design. In addition to the object of the present invention, it is another object of the present invention to provide an FRP molded body that can be formed at a lower cost by preventing defects from occurring due to air accumulation.

[0012]

Means for Solving the Problems In order to achieve the above object, the invention according to claim 1 of the present invention relates to a method of forming a thermosetting transparent resin film or sheet to which a predetermined design has been previously applied, and an FRP molding material. It is characterized by laminating and laminating the laminate under pressure and heat. Further, the invention according to claim 2 is characterized in that the FRP molding material is a sheet molding compound, a thickness molding compound (TM)
C) or bulk molding compound (B
MC).

[0013] With this configuration, the FRP molded body is made of a thermosetting transparent resin film or sheet and an SRP.
It is formed by pressing and heating a laminate formed by laminating MC and the like. Since a thermosetting transparent resin film or the like is disposed on the surface side of the SMC or the like at the time of this molding, the film or the like favorably follows irregularities on the surface of the mold to obtain a stable FRP molded body. In addition, since the predetermined design is provided in advance to the thermosetting transparent resin film or the like, disturbance of the end of the design on the surface of the molded product is prevented, and sufficient linearity is secured at the boundary of the design. ,
Since the film or the like itself has thermosetting properties, the molding process itself is simplified, and an inexpensive FRP molded body can be obtained.

Preferably, the thermosetting transparent resin film or sheet is provided with a predetermined design by printing, as in the third aspect of the present invention. With this configuration, the thermosetting resin film or the like is given a predetermined design such as a pattern by printing such as gravure printing, offset printing, silk printing, sublimation printing, and heat transfer printing. Designs are provided stably and inexpensively.

Further, it is preferable that the thermosetting transparent resin film or sheet has a hole for venting air as in the invention of claim 4. With such a configuration, a non-breathable thermosetting transparent resin film or the like,
By previously forming, for example, fine holes at a predetermined pitch, it is possible to remove air accumulated between the film and the molding material at the time of molding by these holes, and to reliably prevent the occurrence of defective molded articles due to the air accumulation. .

[0016]

Embodiments of the present invention will be described below in detail with reference to the drawings. 1 to 5 show an embodiment in which the FRP molded body according to the present invention is applied to a waterproof pan of a unit bath, FIG. 1 is a plan view of the waterproof pan,
2 is an enlarged view of part A of FIG. 1, FIG. 3 is an explanatory view of a method of forming a waterproof pan, FIG. 4 is a plan view of a main part of the thermosetting transparent resin film, and FIG. FIG.

1 and 2, a waterproof pan 1 is formed, for example, in a rectangular shape in plan view, and a plurality of ribs (not shown) integrally formed between the outer peripheral wall 1a in the front-rear and left-right directions. have. Further, a semicircular concave portion 2 forming a drain port is formed in a central portion on one short side of the waterproof pan 1, and a stone-like pattern portion 3 is formed on the surface thereof. A non-patterned portion 4 is formed on the outer peripheral edge of the SMC 3 by the color of the SMC itself.

Further, in the pattern portion 3, for example, five linear concave grooves 5a to 5e are formed in the front-rear direction, and four linear concave grooves 6a to 6d are formed in the horizontal direction. At the intersections (four places in the figure) where the concave grooves 5a to 5d and the concave grooves 6a to 6d intersect except the central concave groove 5e, a smooth surface 7 as a glossy part is formed. This smooth surface 7
When the surface roughness is measured by a surface roughness meter, the average value of the difference between the concave portion and the convex portion is set to, for example, 5 μm or less. In addition, the surface of the pattern portion 3 other than the smooth surface 7 is formed with a fine uneven surface in order to prevent a bather from slipping, and the average value of the difference between the concave portion and the convex portion is, for example, 30.
It is set to be 0 μm or less.

The waterproof pan 1 is formed as shown in FIG. That is, a thermosetting transparent resin film or sheet 11 (hereinafter, referred to as a film 11 for convenience of description) having a printed portion 11a of a predetermined pattern (design) is placed on the upper surface of the lower mold 9, and on the film 11, SMC12 (or BMC) is placed and laminated as a molding material. As a result, a laminate 13 including the film 11 and the SMC 12 is formed.
The waterproof pan 1 is formed by heating under pressure with the downward pressure. The concave grooves 5a are provided at predetermined positions of the molds 9, 10.
Convex portion 14a and concave portion 14 corresponding to 5e, 6a to 6d
b is provided.

The film 11 is formed of a vinyl ester resin, a polyester resin, an acrylic resin, or the like, and has a thickness of 0.025 to 3.0 mm (preferably 0.1 to 0.3 mm). Its elongation is 140
It is set at 40 to 200% at the time of ° C. The transparency of the film 11 is such that the light transmittance at a thickness of 1 mm is 1
0% or more (preferably 50% or more, more preferably 80% or more)
%).

In these various settings, the thickness is set as follows:
If it is less than 0.025 mm, the waterproof pan 1 will not give a sense of depth,
If it is 3.0 mm or more, it does not follow the shape of the mold at the time of molding. Therefore, if the elongation is set to 10% or less, it will not follow the shape of the mold. When the transparency is set to 10% or less, the waterproof pan 1 cannot have a sense of depth. Further, the film 11 is formed by adding the above resin (or other various resins) to the above resin.
Although a curing agent (accelerating agent as required) that cures at 100 to 150 ° C. is contained, a filler, glass fiber, or the like may be added to the resin as needed.

As shown in FIG. 4, a large number of pores 15 are formed on the film 11 at a pitch p = 20 mm.
Is interposed between the film 11 and the surface of the film 11.

The printing of the film 11 on the printing portion 11a is performed by an appropriate printing method such as gravure printing, offset printing, silk printing, and thermal transfer printing.

Then, the film 1 thus formed
The laminate 13 of the SMC 1 and the SMC 12 is set between the molds 9 and 10 such that the surface of the waterproof pan 1 is on the lower side.
The waterproof pan 1 is formed by pressurizing and heating at a pressure of Pa (10 to 200 kgf / cm ² ).
The temperature of the mold 9 during molding is set to 100 to 160 ° C, and the temperature of the mold 10 is set to 80 to 150 ° C.

In this example, the film 11 is set on the lower mold 9 and the SMC 12 is placed on the film 11.
Was placed to form the laminate 13, but this configuration can be reversed. That is, as shown in FIG. 5, the SMC 12 is set on the lower mold 10, and the film 11 having the printing unit 11 a is placed and set on the SMC 12. Then, the waterproof pan 1 is formed by, for example, lowering the upper mold 9 and performing heating and press molding.

[0026]

Next, an embodiment of the present invention will be described. First, a laminate 13 was prepared from a film 11 having the performance shown in Table 1 below and an SMC 12 having a general composition. And
When the waterproof pan 1 is formed from the laminate 13, the bulge of the boundary L in FIG. 6 is l = 0.4 mm or less, the linearity of the boundary L is sufficiently ensured, and the waterproof pan 1 is sufficiently satisfied. The result was obtained.

[0027]

[Table 1]

[0028]

COMPARATIVE EXAMPLE A waterproof pan 1 was formed from a laminate of a prepreg sheet, a heat-resistant fiber reinforcing material and an SMC as shown in Comparative Examples 1 and 2 in Table 2 below.
In the comparative example 2, the result of 1 = 5 mm was obtained. From these results, it was found that a satisfactory waterproof pan 1 was not obtained in Comparative Example 2, and that Comparative Example 1 was inferior to the above-described Examples, although the linearity of the boundary line L was secured to some extent.

[0029]

[Table 2]

As described above, according to the waterproof pan 1 of the above embodiment, the film 11 having a predetermined thermosetting property and transparency is laminated on the surface side of the molded body of the SMC 12 to form the laminate 13. Since the film 13 is formed by heating and pressurizing, the followability of the film 11 to the molds 9 and 10 becomes good, and the film 11 also follows the concave and convex shapes of the molds 9 and 10 satisfactorily. Is prevented.

Further, the printed portion 1 having a predetermined elongation and heat resistance and having a predetermined pattern is formed on the surface side of the molded body of the SMC 12 in advance.
Since the film 11 having 1a is laminated and formed simultaneously, almost no seepage of the printed portion 11a (pattern portion 3) of the film 11 to the non-print portion (non-pattern portion 4) occurs,
As shown in the embodiment, the disturbance of the boundary line L is extremely small, and a predetermined linearity can be sufficiently secured, and the boundary between the pattern portion 3 and the non-pattern portion 4 can be clarified. .
Further, since the film 11 having a predetermined thickness is disposed on the surface side of the molded body of the SMC 12, the film 11 can obtain a predetermined depth feeling and high gloss by setting the pattern on the surface of the waterproof pan 1 with these films. Thereby, it is possible to easily obtain the waterproof pan 1 having an excellent design and a high quality feeling.

In addition, it is possible to prevent the waterproof pan 1 from being defective due to breakage of the film 11 and the like.
The air interposed between the SMC 12 and the SMC 12 can be evacuated to the outside of the film 11, so that the occurrence of defects due to air accumulation can be prevented, and the defect rate of the waterproof pan 1 can be reduced. Further, since the film 11 has a predetermined thermosetting property in advance, for example, as shown in the conventional molded body E, it is not necessary to apply a binder, and it is possible to prevent the occurrence of defects due to application variations and to improve the conventional various molding methods. The process itself is simplified with respect to the body forming process. As a result, the molding cost can be reduced, and an inexpensive waterproof pan 1 can be easily obtained.

Further, the waterproof pan 1 having excellent chemical resistance and the like due to, for example, chemical resistance and heat resistance of the film 11.
And good quality can be maintained even if the hot water is repeatedly bathed for a long period of time, and a great effect can be expected particularly when applied to various FRP molded articles in a water surrounding space. Further, since the pattern of the film 11 is formed in advance by printing, it is possible to apply the pattern (design) to the film 11 inexpensively and stably, and it is possible to obtain the cheaper waterproof pan 1. Become.

In the above description, the case where the FRP molded body is the main body of the waterproof pan 1 has been described. However, the present invention is arranged in the drain hole of the waterproof pan 1 as shown by a two-dot chain line in FIG. The same can be applied to the semicircular lid 16. In this case, the boundary line L is not a straight line but a curve similar to the concave portion 2 of the waterproof pan 1. Further, the overall shape of the waterproof pan 1, the number and position / shape of the smooth surfaces 7, the shape of the pores 15, the pitch p, and the like are also examples, and within a range not departing from the gist of each invention according to the present invention.
Various changes can be made.

Further, in the above description, an example was described in which the FRP molded body was applied to the waterproof pan 1 of the unit bath. However, the present invention is not limited to this, and can be applied to various FRP molded bodies. In particular, a great effect can be expected when applied to an FRP molded article having a pattern portion also having a slip preventing function or a partially smooth surface.

[0036]

As described above in detail, according to the first aspect of the present invention, since the thermosetting transparent resin film or sheet is disposed on the surface side of the molding material, the film or the like is formed on the surface of the mold. A stable FRP molded body can be obtained by favorably following irregularities. In addition, since the predetermined design is provided in advance to the thermosetting transparent resin film or the like, disturbance of the end of the design on the surface of the molded product is prevented, and sufficient linearity is secured at the boundary of the design, Since the film itself has thermosetting properties, the molding process itself is simplified and the inexpensive F
An RP molded body can be easily obtained.

According to the second aspect of the present invention, in addition to the effects of the first aspect, SMC,
Since TMC and BMC are used, the molding operation itself can be easily performed, and a more inexpensive FRP molded body can be obtained.

According to the third aspect of the invention, in addition to the effects of the first or second aspect of the invention, a predetermined design is provided by printing on the thermosetting transparent resin film or sheet. By printing such as printing, offset printing, silk printing, sublimation printing, and thermal transfer printing, a predetermined design such as a pattern can be stably and inexpensively applied to a film or the like, and a more inexpensive FRP molded body can be obtained.

According to the fourth aspect of the present invention, in addition to the effects of the first to third aspects, since the thermosetting transparent resin film or sheet has holes for venting air, it is possible to use the holes for molding. The air accumulated between the film and the molding material can be evacuated, and the occurrence of molding defects due to the air accumulation can be prevented, so that a more inexpensive FRP molded body can be obtained.

[Brief description of the drawings]

FIG. 1 is a plan view of a waterproof pan for a unit bath as an FRP molded body according to the present invention.

FIG. 2 is an enlarged view of a portion A in FIG. 1;

FIG. 3 is an explanatory view of a method of forming the waterproof pan.

FIG. 4 is a plan view of a main part of the thermosetting transparent resin film.

FIG. 5 is an explanatory view showing another example of the molding method.

FIG. 6 is a plan view showing a conventional waterproof pan.

FIG. 7 is an explanatory diagram of a molding method of the improved type.

[Explanation of symbols]

 1 ... waterproof pan (FRP molded body) 2 ... concave part 3 ... pattern part 4 ... Non-patterned portions 5a to 5e ... groove 6a to 6d ... groove 7 ... smooth surface 9, 10 ... mold 11 ... ... Thermosetting transparent resin film 11a... Printed part 12. Convex part 14b ・ ・ ・ ・ ・ ・ Concave part 15 ・ ・ ・ ・ ・ ・ ・ Pore L ・ ・ ・ ・ ・ ・ ・ ・ ・ Boundary line

 ──────────────────────────────────────────────────続 き Continued on the front page F term (reference) 4F100 AK01A BA02 BA07 DC11A DH02B EJ17B EJ172 EJ422 GB07 HB00 HB00A HB31A JB12A JL02 JN01A

Claims (4)

[Claims] 1. An FRP molded product obtained by laminating a thermosetting transparent resin film or sheet to which a predetermined design has been applied in advance and an FRP molding material, and subjecting the laminated product to pressure and heat molding. 2. The FRP molding according to claim 1, wherein the FRP molding material is formed of a sheet molding compound, a thickness molding compound or a bulk molding compound. 3. The FRP molded product according to claim 1, wherein the thermosetting transparent resin film or sheet has a predetermined design by printing. 4. The FRP molded product according to claim 1, wherein the thermosetting transparent resin film or sheet has holes for venting air.