JP2008265023A - Molded article - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To improve an appearance, workability of molding, and enhance a reinforcement effect. <P>SOLUTION: Reinforcing layer 12 is provided on the back surface side of the bottom surface part 11 of a bathtub 10. The reinforcing layer 12 is formed of a prepreg sheet 17 made by impregnating a resin material in continuous fiber 12A. The viscosity of the resin material in the case when impregnating the resin material in the continuous fiber 12A is set to be 4 Pa. s or less. The continuous fiber 12A is made of a fiber sheet composed of glass cloth or glass mat. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to a molded product, and more particularly to a molded product reinforced with continuous fibers.

  Conventionally, as disclosed in Patent Document 1, a molded article such as a bathtub in which continuous fibers are impregnated with a resin material and reinforced is known. This document discloses a method of compressing and molding a resin material after placing continuous fibers in a mold. In this method, if the viscosity of the resin material is high, the continuous fiber is easily cut when the resin material is impregnated into the continuous fiber, and the continuous fiber is difficult to be impregnated with the resin material, and a sufficient reinforcing effect cannot be obtained. .

  Here, in Patent Document 1, as a method different from the above-described method, a prepreg is prepared in advance using continuous fibers and a resin material, and the reinforcing layer is formed by attaching the prepreg to the back of the bathtub and curing the prepreg. Is disclosed. According to this, at the time of molding, a prepreg containing continuous fibers can be held by hand and placed at an arbitrary position, and the continuous fibers can be easily positioned.

JP 2001-129841 A

Here, this inventor produced the resin material on the conditions substantially the same as Table 1 of patent document 1 in order to produce the said prepreg. As a result, this resin material has a disadvantage that the viscosity is too high to satisfactorily impregnate the continuous fibers, making it difficult to obtain a sufficient reinforcing effect.
In addition, the present inventor carried out the blending under conditions different from the above conditions, that is, the conditions in which the glass fibers were removed from Table 1, which also resulted in the resin material having a high viscosity and the ability to impregnate continuous fibers. Due to the poorness, it was difficult to obtain a sufficient reinforcing effect.

[Object of invention]
The present invention has been devised by paying attention to such inconveniences, and the purpose thereof is to improve the appearance of the appearance, and to reinforce by the reinforcing layer while maintaining good molding workability. It is in providing the molded article which can heighten an effect.

In order to achieve the above-mentioned object, a reinforcing layer formed by impregnating a continuous fiber with a resin material is provided, and the reinforcing layer and the other forming layer are simultaneously formed by compression molding,
The resin material has a viscosity of 4 Pa · s or less when the continuous fiber is impregnated with the resin material.

  In this invention, it is preferable that the said continuous fiber consists of a fiber sheet.

  Moreover, the said reinforcement layer is good to be provided in the back surface side of a molded article.

  According to the present invention, the continuous fiber can be easily impregnated with the resin material, and the uniform impregnation property of the resin material can be improved. As a result, it is possible to avoid the occurrence of defects such as air bubbles and gloss unevenness in the reinforcing layer, it is possible to prevent the reinforcing layer from being defective in appearance, and to improve the strength of the reinforcing layer. Moreover, at the time of molding, the continuous fibers impregnated with the resin material can be easily handled as a prepreg sheet, and the molding operation can be easily performed.

Hereinafter, preferred embodiments of the present invention will be described with reference to the drawings.
In the present specification and claims, unless otherwise specified, “viscosity” means resin in a descup (Sampratec Co., Ltd., product number 1665, PP disc cup, 100 ml) under the condition of a material temperature of 25 ° C. 100 ml of the material is added, and the viscosity is measured using a viscometer (Toki Plating Co., Ltd., digital viscometer (DVU-2 type)).

  The schematic sectional drawing of the bathtub as a molded article which concerns on FIG. 1 is shown by FIG. In this figure, the bathtub 10 has a layered structure including a reinforcing layer 12 provided on the back surface side, that is, the bottom surface side of the bottom surface portion 11 in FIG. 1, and a forming layer 13 that forms other portions. The bottom surface portion 11 is provided with a drainage port 15 made of a hole, and the inner peripheral surface of the drainage port 15 is made of the forming layer 13. The thickness of the bottom part 11 is set to 8 mm.

In the present embodiment, the reinforcing layer 12 is provided in substantially the entire region of the bottom surface of the bottom surface portion 11 and a region that rises slightly from the outer periphery of the region. As shown in FIG. 2, the reinforcing layer 12 includes continuous fibers 12 </ b> A inside. The continuous fiber 12A is made of a fiber cloth composed of a glass cloth woven with warp and weft or a glass mat that is a non-woven fabric. The basis weight of the continuous fiber 12A is set to 250 to 1200 g / m ² . The thickness of the reinforcing layer 12 is set to 0.3 mm or more, preferably 0.5 mm or more, and more preferably 0.7 mm or more in order to obtain a reinforcing effect.

  The reinforcing layer 12 is formed of a prepreg sheet 17 (see FIG. 3) produced by impregnating the continuous fiber 12A with a resin material. When the prepreg sheet 17 is manufactured, the viscosity of the resin material is set to 4 Pa · s or less, preferably 2.5 Pa · s or less, and more preferably 1.5 Pa · s or less. By setting the viscosity to 4 Pa · s or less, the uniform impregnation of the resin material into the continuous fiber 12A becomes excellent, and the appearance and the strength of the bottom surface portion 11 can be stably improved. it can.

The amount of the resin material applied is set so that the resin impregnation rate obtained by Equation 1 described later is 80 to 160%, preferably 95 to 130%. By setting within this range, even if the viscosity of the resin material changes during molding, it is possible to avoid the continuous fiber 12A from being cut or the generation of bubbles and uneven gloss in the reinforcing layer 12. If the resin impregnation rate is less than 80%, the entire surface of the continuous fiber 12A cannot be impregnated with the resin material.
Here, by setting the basis weight of the continuous fibers 12A to 580 g / ^{m 2,} with the amount of the resin material, 0.464kg / ^{m 2} with 80% resin impregnation ratio, 0.93 kg ^{/ m} 2 at 160% resin impregnation ratio, When the resin impregnation rate is 95%, it becomes 0.55 kg / m ² , and when the resin impregnation rate is 130%, it becomes 0.755 kg / m ² .

  The resin material is blended with a filler made of aluminum hydroxide or the like as required. By adjusting the blending amount of the filler, the impregnation property of the resin material into the continuous fibers 12A can be adjusted, and the curing shrinkage rate at the time of molding can be adjusted. The filler is set to less than 100 parts by weight, preferably 50 parts by weight or less, and more preferably 1 part by weight or less with respect to 100 parts by weight of a thermosetting resin such as unsaturated polyester. According to this, it is possible to avoid an increase in the difference in shrinkage between the resin material and the compression molding material, which will be described later, of the forming layer 13, and the reinforcing layer 12 and the forming layer 13 are easily distorted and easily broken. Can be prevented.

  A curing agent is blended in the resin material. The curing agent includes one whose decomposition temperature is set to a condition of ± 10 ° C. of the decomposition temperature of the curing agent used in the compression molding material described later of the bathtub forming layer 13, and this is the total curing agent of the resin material. The ratio is set to 50% or more.

  The formation layer 13 is formed of a compression molding material 18 (see FIG. 3) made of BMC. The compression molding material 18 preferably has the same color as the resin material. Specifically, the color difference from the resin material is set to ΔE = 10 or less.

  The bathtub 10 is compression-molded using a mold 20 shown in FIG. The mold 20 includes an upper mold 23 and a lower mold 24 that form a cavity space 22 having a shape corresponding to the bathtub 10 inside. The upper mold 23 forms the product surface side of the bathtub 10, while the lower mold 24 forms the back surface side of the bathtub 10. A protrusion 26 for forming the drain port 15 is formed on the cavity space 22 side of the lower mold 24.

In compression-molding the bathtub 10, a prepreg sheet 17 is produced. In this preparation, first, in addition to an internal mold release agent such as zinc stearate, a thickener made of a metal compound or an isocyanate compound, water and styrene are blended in a predetermined ratio with a thermosetting resin made of an unsaturated polyester resin or the like. And a filler is mix | blended as needed and a resin material is produced.
Next, a process of defoaming the resin material is performed while impregnating the produced resin material into the continuous fibers 12A. In this treatment, the produced resin material is applied to the release film with a brush, and the continuous fiber 12A is placed thereon, and then the resin material is applied to the continuous fiber 12A, and then the release film is covered with a roller. Press.
Thereafter, the continuous fiber 12A impregnated with the resin material is placed in a 40 ° C. aging furnace and left for 36 hours to increase the viscosity, whereby the prepreg sheet 17 is produced. In the thickening treatment, at least one surface of the continuous fiber 12A impregnated with the resin material may be covered with the release film, and preferably both surfaces are covered with the release film.

  The compression molding material 18 is produced before and after the production of the prepreg sheet 17. In this production, the respective materials are blended in the proportions shown in Table 1 below, kneaded using a planetary mixer and extruded, then placed in a 40 ° C. aging furnace for 36 hours to increase the viscosity.

Before putting the prepreg sheet 17 and the compression molding material 18 into the molding die 20, the cavity space 22 side of the upper die 23 is heated to 145 ° C., and the cavity space 22 side of the lower die 24 is heated to 130 ° C. Further, a release agent is applied to the cavity space 22 side of the upper mold 23 and the lower mold 24.
Next, the prepreg sheet 17 from which the release film has been peeled is set in the lower mold 24. At this time, the prepreg sheet 17 is cut in advance to a size such that the reinforcing layer 12 is located in the region described above. Moreover, the hole 17A is provided in the position corresponding to the said protrusion part 26 of the prepreg sheet 17, and the prepreg sheet 17 is positioned by inserting the protrusion part 26 in this hole 17A. The hole 17 </ b> A is formed in a size that does not contact the protruding portion 26.
Thereafter, the compression molding material 18 is placed on the prepreg sheet 17, the upper mold 23 and the lower mold 24 are tightened, and the prepreg sheet 17 and the compression molding material 18 are simultaneously compressed. By performing mold clamping for 480 seconds and then removing the mold, the bathtub 10 in which the reinforcing layer 12 is integrated is obtained.

  Examples of the present invention will be described below together with comparative examples.

[Examples 1-5, Comparative Examples 1-3]
In Examples 1 to 5 and Comparative Examples 1 to 3, a resin material is prepared by blending each material in the ratio shown in Table 2, and this resin material is a continuous fiber 12A made of a glass cloth having a basis weight of 580 g / m ^2. A prepreg sheet impregnated with was used. In Table 2, an unsaturated polyester resin having a styrene content of 35 to 36% was used, and aluminum hydroxide having an average particle diameter of 25 μm subjected to silane coupling treatment was used. The compression molding material 18 and the molding method were the same as those in the above embodiment.
In Comparative Example 1, a resin material was produced under substantially the same conditions as in Table 1 of Patent Document 1 described above, and in Comparative Example 2, a resin material was produced under conditions obtained by removing glass fibers from Table 1 of the same document.

  In each Example and each Comparative Example, the viscosity of the resin material when the continuous fiber 12A was impregnated with the resin material and the amount of the resin material used per unit area were measured. The results are shown in Table 3. In Table 3, the viscosity A was measured under the conditions of a material temperature of 25 ° C. and a rotation speed of 50 rpm, and the viscosity B was measured under the conditions of a material temperature of 37.5 ° C. and a rotation speed of 50 rpm. Viscosity measuring rotor No. was 5 in Examples 1 to 5 and 7 in Comparative Examples 1 to 3.

As shown in Table 4 below, each performance of each example and each comparative example was compared and evaluated.
The impregnation properties in Table 4 evaluated the ease of impregnation into the continuous fiber 12A in the resin material. In this evaluation, “xx” represents a state where the viscosity cannot be measured well due to the influence of the fiber, and the viscosity is too high to be satisfactorily impregnated. “X” represents a state in which the viscosity A is as very high as 100 Pa · s or more, so that the impregnation property is very poor and the continuous fiber 12A cannot be uniformly impregnated with the resin material. “◯” indicates a state where the impregnation property is good and the continuous fiber 12A is uniformly impregnated with the resin material, and “◎” indicates that the impregnation property is particularly good and the continuous fiber 12A is uniformly impregnated with the resin material. is there. “Δ” is an intermediate state between “×” and “◯”.
As in Comparative Example 2, when the use amount of 1.8 kg / m ² becomes a required impregnation property, a prepreg sheet 17 in which unevenness occurs in the resin material to be impregnated is produced, and at the time of molding using the resin material, In many places, the resin material flows out, and where there is little resin material, the impregnation is poor even after molding.
In Examples 1 to 5, the inside of the continuous fiber 12A is impregnated with a resin material to be transparent, and in the evaluation of “◎”, the impregnating properties are good in the order of Example 3, Example 4, and Example 5. As a result. In Examples 4 and 5, the use amount was as small as 0.65 kg / m ^2, and the impregnation property was sufficient.

The appearance of the reinforcing layer 12 in Table 4 was evaluated by visually observing the reinforcing layer 12 after molding from the outside. In this evaluation, “x” represents a state where many portions of the reinforcing layer 12 not impregnated with the resin material can be visually recognized. “◯” represents a state where a portion of the reinforcing layer 12 that is not impregnated with the resin material cannot be visually recognized, and “Δ” represents a state where the portion of the reinforcing layer 12 that is not impregnated with the resin material is visually small.
In Examples 1 to 5, the reinforcing layer 12 having a beautiful appearance without bubbles was formed. In Comparative Examples 1 to 3, there was a variation in the appearance. Therefore, in Comparative Examples 1 to 3, it is expected that the strength also varies.

  The handling properties in Table 4 are due to thickening and are evaluations of the ease of handling of the prepreg sheet 17 and the ease of peeling from the release film. In this evaluation, “◯” represents a state in which the workability of molding is good, and “◎” represents a state in which the workability is particularly good.

[Examples 6 and 7, Comparative Examples 4 and 5]
In Examples 6 and 7, compared to Examples 2 and 4, the continuous fiber 12A was changed to a glass mat with a basis weight of 450 g / m ² , and the amount of resin material used per unit area was set to 500 g / m ² . In Comparative Examples 4 and 5, the molding was performed on Examples 2 and 6 without impregnating the continuous fiber 12A with the resin material.

  A sand bag impact test was performed on the bottom surface portions 11 of Examples 2, 4, 6 and 7, and Comparative Examples 4 and 5. This test was evaluated by dropping a 7 kg sand bag from three different heights of 1 m, 1.5 m, and 2 m onto the bottom surface portion 11 and observing the back surface side of the bottom surface portion 11.

In Examples 2 and 4, the reinforcing layer 12 did not change even when the sand bag was dropped from any height. In Examples 6 and 7, when the sand bag was dropped from a height of 1 m and 1.5 m, there was no change in the reinforcing layer 12, but when the sand bag was dropped from a height of 2 m, the reinforcing layer 12 was A minute crazing occurred.
In Comparative Example 4, when the sand bag was dropped from a height of 1 m, the back surface of the bottom surface portion 11 was cracked. Therefore, the test at a height of 1.5 m and 2 m was not performed. In Comparative Example 4, a part of the glass cloth was cut due to the pressure during molding. In Comparative Example 5, when the sand bag was dropped from a height of 1 m, a crack penetrating the front and back of the bottom surface portion 11 occurred. Therefore, the test at a height of 1.5 m and 2 m was not performed. In Comparative Example 5, the glass mat was cut by the pressure during molding.

  It can be understood that Examples 2, 4, 6 and 7 can be set to a sufficient strength by reinforcing the bottom surface portion 11 with the reinforcing layer 12 as compared with Comparative Examples 4 and 5. Also, according to the sand bag impact test, Examples 2 and 4 have better strength than Examples 6 and 7, and the continuous fiber 12A has a glass cloth better strength than a glass mat. Understandable.

Although the best configuration, method and the like for carrying out the present invention have been disclosed in the above description, the present invention is not limited to this.
That is, the present invention has been particularly shown and described with respect to particular embodiments, but is not limited to the embodiments described above without departing from the scope and spirit of the present invention. In other detailed configurations, those skilled in the art can make various modifications.
Therefore, the description limited to the shape disclosed above is an example for easy understanding of the present invention, and does not limit the present invention. The description by the name of the member which remove | excluded one part or all part is included in this invention.

For example, the formation position of the reinforcing layer 12 can be variously changed and formed so as to be within the surface of the bottom surface portion 11, partially formed on the bottom surface portion 11, or on the entire back surface side of the bathtub 10. Or may be formed.
Further, the present invention is not limited to a bathtub, but as a molded product having a bottomed container shape such as a bowl, a sink, a waterproof pan, or a molded product having a shape extending in a substantially horizontal direction such as a kitchen counter or a bathroom counter. Also good.

The schematic longitudinal cross-sectional view of the bathtub which concerns on embodiment. The A section enlarged view of FIG. The schematic longitudinal cross-sectional view of the shaping | molding die of the said bathtub.

Explanation of symbols

  10 ... bathtub, 12 ... reinforcing layer, 12A ... continuous fiber

Claims (3)

A reinforcing article formed by impregnating a continuous fiber with a resin material is formed, and the reinforcing layer and the other forming layer are simultaneously formed by compression molding,
A molded product, wherein the viscosity of the resin material when the continuous fiber is impregnated with the resin material is set to 4 Pa · s or less.   The molded article according to claim 1, wherein the continuous fiber comprises a fiber sheet.   The molded product according to claim 1, wherein the reinforcing layer is provided on a back surface side of the molded product.

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