JP2002355892A - Frp molded product and method for manufacturing the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To simply and inexpensively manufacture a shaped article or the like having a shape and a figure simulating the shape and figure of irregular/ amorphous existing matter from FRP in a multikind and small-quantity production scale for a short time. SOLUTION: Both surfaces of a metal net made of stainless steel with a wire diameter of 2 mm and a pitch of 9 mm are covered with glass cloths and a resin support having a film applied to one surface thereof is molded into rock-like shape and the molded product is coated with an unsaturated polyester resin with a viscosity of 400 (Mps.s) and an over hang for preventing the running of the resin, the so-called an inverted taper part is attached to the coated molded product at a predetermined place to cure the molded product.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing an FRP molded article and an FRP molded article. More specifically, the present invention relates to a method of manufacturing an FRP molded article which is relatively small without using a wooden mold and recalls an arbitrary shape or aesthetic beauty, and an FRP molded article.

[0002]

2. Description of the Related Art A liquid resin such as polyester resin, epoxy resin, urethane resin and diallyl phthalate resin and a reinforcing material such as glass fiber, glass cloth and glass fiber powder added thereto is called fiber reinforced plastic (FRP). Since it can be easily molded at low pressure and has the highest impact strength among various plastics, it is used to produce sports car bodies, glider bodies, yachts, boat hulls, corrugated plates, flat plates, rain gutters, and the like.

[0003] Conventionally, FRP molded products are made by laminating glass mats, glass cloths and the like on a wooden mold and impregnating the resin, a so-called hand lay-up method, by laminating a glass cloth impregnated with a resin, Vacuum molding method, in which vacuum is applied to form a close contact, molding, resin cloth impregnated glass cloth, and pressure air molding method, in which compressed air is blown and blown to form a close contact, resin cloth impregnated glass cloth is overlapped and pressed with a mold Matched die molding method, a glass mat, a method of laminating a glass mat, placing it in a mold, pressing a mixture of a resin and a curing agent into it, molding it, mixing a glass roving, resin and a curing agent , A method in which the resin is impregnated into a pipe by blowing it out of a separate nozzle onto the surface of the mold They are manufactured in such a filament winding method for forming wound. Further, a glass fiber or a glass cloth impregnated with a phenol resin, an epoxy resin, a diallyl phthalate resin or the like is put in a mold, and heated and pressed to produce gears, insulating plates, safety hats, and the like.

[0004] These conventional methods are suitable for demanding strict standards or for producing relatively large molded products in large quantities. However, if it is not necessary to manufacture a large number of products of the same standard, or a small amount of irregularly or irregularly shaped objects that contribute to beautification of the environment and landscape, such as artificial rocks, objects that recall an abstract image, etc. In such a case, the above-described conventional technology cannot be used, and if used, the production cost is disadvantageously increased.

[0005] One of the above-mentioned conventional methods will be described in detail.
For example, when performing a desired shaping process on a large wall such as in an amusement park such as Disneyland, the wall is first assembled with a steel frame. On the other hand, separately, a liquid resin such as polyester resin, epoxy resin, urethane resin, diallyl phthalate resin is poured into the female mold, reinforced with glass fiber, cured, removed from the female mold, and shaped into the desired shape. After cutting, it was attached to a steel frame that had been assembled in advance by an arbitrary means such as an adhesive or a bolt, and the joint was embedded with a resin and then painted.

[0006] This conventional method has an advantage that a successful molded article having the same shape can be manufactured because a female mold is used, but a mold margin is required. It costs the whole cost. Due to the manufacture by the mold, the reverse taper cannot be formed. Since the joint portion is processed later, there is a disadvantage that inconsistency with a portion manufactured by a mold occurs.

[0007]

Accordingly, the main problem to be solved by the invention is that when it is not necessary to manufacture a large number of products of the same standard, it is possible to manufacture them easily and inexpensively using FRP. That was not the point.

[0008] Another problem to be solved by the invention is environmental and environmental problems.
Irregular / irregular shaped objects that contribute to landscape beautification, such as artificial rocks and objects reminiscent of abstract images.
When manufacturing with RP, it was not able to manufacture easily, in a short time and at low cost. Other problems and advantages to be solved by the invention will be clarified below.

[0010]

In order to solve the above-mentioned problems, the present invention provides, instead of using a female mold, (a) a core material which can be formed into an arbitrary shape by penetrating a liquid thermosetting resin. A resin support coated on both sides with a glass cloth, (b) a core material capable of being penetrated by a liquid thermosetting resin and formed into an arbitrary shape was coated on one side with a glass cloth, and the other side was coated with a film. A resin support, (c) a resin support in which one surface of a core material which can be formed into an arbitrary shape by penetrating a liquid thermosetting resin, or (d) penetrating a liquid thermosetting resin. A resin support was used in which both sides of a core material that can be formed into the shape described above were covered with glass cloth and one side was further covered with a film.

The core material used in the present invention, which can be formed into an arbitrary shape by penetrating the liquid thermosetting resin, is mainly formed into an arbitrary shape by human power, and the shape is continuously maintained, and Is defined as a material which allows the liquid thermosetting resin applied to the surface to penetrate from the surface and has the same function as a mold conventionally used in the FRP field, for example, a wooden mold.

The core material that can be formed into an arbitrary shape by infiltrating the liquid thermosetting resin used in the present invention as defined above is:
It is a wire mesh, a perforated metal and a wire made of iron wire, steel wire, steel strip, stainless steel.

Accordingly, a preferred resin support for use in the present invention is (a) a resin support in which both surfaces of a stainless steel wire mesh are covered with glass cloth, and (b) one surface of the stainless steel wire mesh which is covered with glass cloth. A resin support having the other surface covered with a film, (c) a resin support having one surface of a stainless steel wire mesh covered with a film, or (d) both surfaces of a stainless steel wire mesh covered with glass cloth. Is a resin support having the surface covered with a film.

In the preferred resin supports used in the present invention described above, (b), (c) and (d) have the outer layer covered with a film. This has the effect of preventing dripping of the liquid thermosetting resin applied to the surface. Therefore, it can be said that a resin support in which the outer layer is covered with a film is more preferable.

The term "resin support pair" used in the present invention is not a term established in the art, but is a term coined by the present inventor. Holding a polyester resin of a predetermined viscosity,
An object to be coated with a liquid resin such as an epoxy resin, a urethane resin, and a diallyl phthalate resin. After the resin is cured, the glass cloth and the resin, which are one of the components, are integrated to form an FRP. Define.

The resin support pair used in the present invention, in which the surface of a core material which can be formed into an arbitrary shape by penetrating the liquid thermosetting resin, is coated with a glass cloth and / or film, is extremely flexible and can be manually operated. And the shape can be continuously maintained. The arbitrary shape mentioned here is
Hard wood molds include three-dimensional, cuboid, spherical, circular, polygonal, or a complex combination of these, including animals that have an inverse tapered shape that cannot be removed after hardening, or animals or natural products Includes existing objects such as abstract shapes with new shapes and structures, shapes simulating shapes, and imaginary shapes.

[0017]

Embodiments of the present invention will be described below with reference to examples.

EXAMPLE 1 A resin support having a stainless steel wire mesh having a wire diameter of 2 mm and a pitch of 9 mm and having glass cloth coated on both sides was used for 10
The resin support was shaped like a rock, and an unsaturated polyester resin having a viscosity of 400 (Mpa · s) was applied thereto. An overhang for preventing resin dripping, a so-called reverse tapered portion, was attached to a predetermined location. It hardened into pseudo rock in about 5 hours.

[0018]

Example 2 Ten resin supports each having a wire diameter of 2 mm and a pitch of 9 mm covered with a glass cloth on one side of a stainless steel wire mesh and the other side covered with a film were manufactured. And a viscosity of 1000 (Mpa)
-Epoxy of s) was applied. An overhang for preventing resin dripping, a so-called reverse taper portion, was attached to a predetermined location. It hardened into pseudo rock in about 24 hours.

[0019]

EXAMPLE 3 A resin support having a wire diameter of 2 mm and a pitch of 9 mm and one side of a stainless steel wire mesh covered with a film was covered with 10
This resin support was shaped like a rock, and a urethane resin having a viscosity of 1500 (Mpa · s) was applied thereto.
An overhang for preventing resin dripping, a so-called reverse taper portion, was attached to a predetermined location. It hardened in about 10 hours and became a pseudo rock.

[0020]

Example 4 Ten resin supports each having a stainless steel wire net having a wire diameter of 2 mm and a pitch of 9 mm covered with glass cloth and one surface covered with a film were manufactured. It is shaped and this has a viscosity of 400 (Mpa
-The unsaturated polyester resin of s) was applied. An overhang for preventing resin dripping, a so-called reverse taper portion, was attached to a predetermined location. It hardened into pseudo rock in about 5 hours.

[0021]

According to the first aspect of the present invention, since a resin support having glass cloth coated on both sides is used, the thermosetting resin and the glass cloth on both sides are integrated to form a strong FRP molded product. Manufactured.

According to the second aspect of the present invention, since a resin support having one surface coated with glass cloth and the other surface coated with a film is used, the effect of preventing the liquid thermosetting resin from sagging can be obtained. Accordingly, a strong FRP molded product integrated with the glass cloth is manufactured.

According to the third aspect of the present invention, since a resin support in which one surface of a wire mesh made of stainless steel is coated with a film is used, an FRP molded article having an effect of preventing dripping of a liquid thermosetting resin. Is manufactured.

According to the fourth aspect of the present invention, since a resin support in which both surfaces of the wire mesh made of stainless steel are covered with glass cloth and one surface is further covered with a film is used, dripping of the liquid thermosetting resin is performed. A strong FRP molded product integrated with the glass cloth is produced with the effect of preventing it.

According to the fifth aspect of the present invention, a preferable core material is provided, and the opportunity for carrying out the present invention is expanded.

According to the fifth aspect of the present invention, an irregular or irregular shaped object which does not conform to the same standard but contributes to beautification of the environment and landscape, for example, a pseudo rock, a shaped object reminiscent of an abstract image, etc. It can be provided simply, in a short time and at low cost.

──────────────────────────────────────────────────の Continued on the front page (51) Int.Cl. ⁷ Identification code FI Theme coat ゛ (Reference) B29K 105: 22 B29C 67/14 U (72) Inventor Yu Matsumoto 2-2-1 Matsuhamacho, Fukuyama City, Hiroshima Prefecture Hiroshima Kasei Co., Ltd. (72) Inventor Takahide Akiyama Esuna Building, 2-15-5 Higashi 2-chome, Shibuya-ku, Tokyo (72) Inventor Masakazu Okubo 417 Shimoda, Hino-shi, Tokyo F-term ( (Reference) 4F072 AA07 AB09 AB11 AB28 AB30 AD23 AD38 AD43 AG03 AG12 AH04 AH25 AK03 AK20 AL01 4F205 AA36 AD15 AD16 AD35 AG05 AH44 HA10 HA29 HA33 HA35 HA40 HA43 HB01 HG04 HM02 HT13 HT14

Claims (6)

[Claims] 1. A resin support in which a liquid thermosetting resin is infiltrated and a core material capable of being formed into an arbitrary shape is coated on both sides with a glass cloth into an arbitrary shape, and the liquid thermosetting resin is formed on the surface of the resin support. A method for producing an FRP molded product, comprising curing after application. 2. A resin support in which one side of a core material which can be formed into an arbitrary shape by penetrating a liquid thermosetting resin is coated with a glass cloth and the other surface is coated with a film. Thereafter, a liquid thermosetting resin is applied to the surface of the resin, followed by curing, to produce an FRP molded product. 3. A resin support in which a liquid thermosetting resin is impregnated and one side of a core material which can be formed into an arbitrary shape is coated with a film, and the resin support is formed into an arbitrary shape. A method for producing an FRP molded product, comprising curing after application. 4. A resin support in which a liquid thermosetting resin is impregnated into a core material which can be formed into an arbitrary shape, and both surfaces of which are covered with glass cloth and one surface of which is further coated with a film are formed into an arbitrary shape. A method for producing an FRP molded product, comprising applying a thermosetting resin to the surface and then curing the resin. 5. The method according to claim 1, wherein the core material is an iron wire, a steel wire, a steel strip, a wire mesh made of stainless steel, a punching metal, and a wire. . 6. An FRP molded article manufactured by the method according to claim 1.