JP2018008461A - Method for producing frp molded article - Google Patents

Method for producing frp molded article Download PDF

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JP2018008461A
JP2018008461A JP2016139855A JP2016139855A JP2018008461A JP 2018008461 A JP2018008461 A JP 2018008461A JP 2016139855 A JP2016139855 A JP 2016139855A JP 2016139855 A JP2016139855 A JP 2016139855A JP 2018008461 A JP2018008461 A JP 2018008461A
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decorative
decorative sheet
frp
molded product
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JP6542723B2 (en
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地 哲 雄 菊
Tetsuo Kikuchi
地 哲 雄 菊
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TOYU GIKEN KK
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Abstract

PROBLEM TO BE SOLVED: To provide a decorative sheet sealing method which can sufficiently utilize a design without breaking a decorative sheet, foaming a gap and impairing unevenness and feeling.SOLUTION: A method for sealing a decorative sheet S includes successively forming a transparent clear coat layer 4 to be the outermost surface, a decorative layer 3 and an FRP layer 2 formed into a base material on a molding surface 5a figuring a surface of an FRP molded article 1. The method includes flowing a transparent surface side sealing resin 7a sealing a surface side of the decorative sheet S onto the clear coat layer 4, mounting the decorative sheet S on a liquid surface of the resin before the resin disappears its flowability to seal a liquid phase on the surface side of the decorative sheet, flowing a transparent rear face side sealing resin 8 sealing a rear face side of the decorative sheet S to seal a liquid phase on the rear face side of the decorative sheet (S), and curing the respective resins 7 and 8.SELECTED DRAWING: Figure 1

Description

本発明は、繊維強化樹脂(以下「FRP」と言う。)の表面に加飾が施されたFRP成形品の製造方法に関する。   The present invention relates to a method for producing an FRP molded product in which a surface of a fiber reinforced resin (hereinafter referred to as “FRP”) is decorated.

従来より、加飾されたFRP成形品の製造方法として、加飾シートを透明樹脂の間にインサート成形する方法が知られている(特許文献1)。
これは、透明樹脂を予めシート状に形成し、加飾シートが樹脂シートの間に位置するように樹脂シートと加飾シートを積層した状態で、140〜150℃に加熱した型の間に挟んで、100kg/cmで240秒間、加熱加圧成形するようにしている。
この方法によれば、透明樹脂の内部に加飾シートが封入されているので、成形品の表面に加飾シートが配されているのと異なり、深み感、透明感、高級感があり、擦れや水濡れにより加飾部分が削れたり汚れたりすることがない。
Conventionally, as a method for producing a decorated FRP molded product, a method of insert molding a decorative sheet between transparent resins is known (Patent Document 1).
This is done by forming a transparent resin into a sheet shape in advance and sandwiching the resin sheet and the decorative sheet so that the decorative sheet is positioned between the resin sheets, and sandwiching it between the molds heated to 140-150 ° C. Thus, heating and pressing are performed at 100 kg / cm 2 for 240 seconds.
According to this method, since the decorative sheet is enclosed inside the transparent resin, unlike the decorative sheet disposed on the surface of the molded product, there is a sense of depth, transparency, luxury, and rubbing. The decorative part will not be scraped or soiled by water or water.

ところで最近では、このようなFRP成形品の加飾シートとして、織物、その他の表面に凹凸のある高級素材を用いた試みがなされている。
しかしながら、例えば西陣織のようなやわらかな凹凸模様を有する高級素材を加飾シートとして用いた場合に、100kg/cmもの高圧で加圧成形すると、素材の凹凸が完全に潰れてしまい、西陣織の高級感が損なわれてしまうため、そのような加飾シート特有の意匠を生かすことができないという問題があった。
また、フラットな着色シートや金箔などの極薄の加飾シートを封入樹脂の間に挟んで加圧する際に、圧力過多で加飾シートが破れたり、圧力不足で封入樹脂と加飾シートとの間にわずかな隙間ができてしまい、いずれにしろ高級感を損なうという問題があった。
By the way, recently, attempts have been made to use a high-grade material having irregularities on the surface of a woven fabric or other surface as a decorative sheet for such an FRP molded product.
However, for example, when a high-grade material having a soft uneven pattern such as Nishijin weave is used as a decorative sheet, if the pressure molding is performed at a high pressure of 100 kg / cm 2 , the unevenness of the material is completely crushed, and Nishijin weave Since a feeling is impaired, there existed a problem that the design peculiar to such a decorating sheet could not be utilized.
In addition, when a very thin decorative sheet such as a flat colored sheet or gold foil is sandwiched between the encapsulated resins and pressed, the decorative sheet is torn due to excessive pressure, or between the encapsulated resin and the decorative sheet due to insufficient pressure. There was a problem that a slight gap was formed between them, and anyway, the sense of quality was impaired.

特開平8−174581号公報JP-A-8-174581

そこで本発明は、加飾シートを封入する際に、加飾シートが破れたり、隙間が形成されることなく、また、加飾シートの凹凸や風合を損なうことなく、その意匠を十分に生かすことができるようにすることを技術的課題とする。   Therefore, when enclosing a decorative sheet, the present invention makes full use of the design without tearing the decorative sheet or forming a gap, and without impairing the unevenness and texture of the decorative sheet. It is a technical problem to make it possible.

この課題を解決するため、本発明は、表層側に形成される加飾層内に加飾シートを封入するFRP成形品の製造方法において、
前記成形品の表面形状を模る型表面に、当該成形品の表層となる透明なクリアコート層を形成するクリアコート層形成工程と、
クリアコート層の上に加飾シートの表面側を封入する透明の表面側封入樹脂を流し入れ、当該樹脂が流動性を消失する前にその液面に加飾シートを載置し、載置された加飾シートの上に当該加飾シートの裏面側を封入する透明の裏面側封入樹脂を流し入れて、前記加飾シートを液相内に封入した加飾層を形成する加飾層形成工程と、
前記加飾層形成工程で流し入れた透明樹脂の流動性を消失させる予備硬化工程と、
前記予備硬化工程で流動性が消失された加飾層の上に少なくとも一層のFRP層を積層成形するFRP層形成工程と、
FRP層形成工程が完了した成形品を放置あるいは加熱して硬化させる成形品硬化工程と、
を備えたことを特徴とする。
In order to solve this problem, the present invention provides an FRP molded product manufacturing method in which a decorative sheet is enclosed in a decorative layer formed on the surface layer side.
A clear coat layer forming step of forming a transparent clear coat layer to be a surface layer of the molded product on the mold surface imitating the surface shape of the molded product;
A transparent surface-side encapsulating resin that encapsulates the surface side of the decorative sheet is poured onto the clear coat layer, and the decorative sheet is placed on the liquid surface before the resin loses fluidity. A decorative layer forming step of forming a decorative layer in which a transparent back side encapsulating resin encapsulating the back side of the decorative sheet is poured on the decorative sheet and the decorative sheet is enclosed in a liquid phase;
A pre-curing step for eliminating the fluidity of the transparent resin poured in the decorative layer forming step;
An FRP layer forming step of laminating and forming at least one FRP layer on the decorative layer whose fluidity has been lost in the preliminary curing step;
A molded product curing step in which the molded product in which the FRP layer forming process is completed is left or heated to be cured;
It is provided with.

本発明に係るFRP成形品の製造方法によれば、透明の表面側封入樹脂の液面に加飾シートを載置し、その上から透明の裏面側封入樹脂を流し入れることとしているので、加飾シートの表面側は液状の表面側封入樹脂に接して液相封入され、裏面側は液状の表面側封入樹脂に接して液相封入される。
このように、液相の封入樹脂と加飾シートが接触するので、封入樹脂と加飾シートとの間に隙間が形成されることがない。
また、加飾シートに柔らかな凹凸が形成されている場合であっても、無加圧状態で加飾シートの凹凸内に液状の樹脂が入り込み、その凹凸が潰されることはない。
According to the method for manufacturing an FRP molded product according to the present invention, the decorative sheet is placed on the liquid surface of the transparent front-side encapsulating resin, and the transparent back-side encapsulating resin is poured from above. The surface side of the sheet is in liquid phase encapsulation in contact with the liquid surface side encapsulating resin, and the back surface side is in liquid phase encapsulation in contact with the liquid surface side encapsulating resin.
Thus, since the liquid-phase encapsulating resin and the decorative sheet are in contact with each other, no gap is formed between the encapsulating resin and the decorative sheet.
Further, even when soft irregularities are formed on the decorative sheet, the liquid resin does not enter the irregularities of the decorative sheet in a non-pressurized state, and the irregularities are not crushed.

また、加飾シートを液相封入した加飾層が硬化した後に、当該加飾層の上にFRP層を積層形成することとしているので、FRP層を形成するときに加飾層に圧力が作用したとしても、加飾シートは硬化した加飾層内に保持されているので、その圧力で加飾シートの凹凸が潰されることがない。
したがって、加飾シートとして、表面に柔らかな凹凸のある西陣織のような高級素材を用いた場合でも、織地の凹凸や風合が損なわれず、加飾シートの意匠を十分に生かすことができる。
In addition, since the FRP layer is formed on the decorative layer after the decorative layer in which the decorative sheet is liquid-sealed is cured, pressure acts on the decorative layer when the FRP layer is formed. Even if it did, since the decorating sheet is hold | maintained in the hardening decorating layer, the unevenness | corrugation of a decorating sheet is not crushed by the pressure.
Therefore, even when a high-grade material such as Nishijin weave having soft unevenness on the surface is used as the decorative sheet, the unevenness and texture of the texture are not impaired, and the design of the decorative sheet can be fully utilized.

本発明方法を示す説明図。Explanatory drawing which shows this invention method. 図1(e)の拡大図。The enlarged view of FIG.1 (e). 型入れが完了した状態を示す説明図。Explanatory drawing which shows the state which mold insertion was completed. 本発明方法で製造されたFRP成形品の模式図Schematic diagram of FRP molded product manufactured by the method of the present invention 実施例2を示す説明図。FIG. 6 is an explanatory diagram showing Example 2. 実施例2において型入れが完了した状態を示す説明図。Explanatory drawing which shows the state which the mold insertion completed in Example 2. FIG. 実施例2で製造されたFRP成形品の模式図Schematic diagram of FRP molded product manufactured in Example 2

本例は、加飾シートを封入する際に、加飾シートが破れたり、隙間が形成されることなく、また、加飾シートの凹凸や風合を損なうことなく、その意匠を十分に生かすことができるようにするために、FRP成形品の表層側に形成される加飾層に加飾シートを液相封入することとした。
具体的には、成形品の表面を模る型表面に、当該成形品の表層となる透明なクリアコート層を形成した後、クリアコート層がある程度硬化した時点で、加飾層を形成する。
In this example, when the decorative sheet is encapsulated, the decorative sheet is not torn or a gap is not formed, and the design is fully utilized without impairing the unevenness and texture of the decorative sheet. In order to make it possible, the decorative sheet is liquid-sealed in the decorative layer formed on the surface layer side of the FRP molded product.
Specifically, after forming a transparent clear coat layer as a surface layer of the molded product on the mold surface imitating the surface of the molded product, a decorative layer is formed when the clear coat layer is cured to some extent.

加飾層は、まず、クリアコート層の上に加飾シートの表面側を封入する透明の表面側封入樹脂を流し入れ、当該樹脂が流動性を消失する前にその液面に加飾シートを載置する。
これにより、加飾シートの表面側は液状の樹脂に接し、加飾シートに柔らかな凹凸が形成されている場合でも、凹凸がつぶれることがなく、また、凹んだところまで樹脂が入り込み、表面側が液相封入されることとなる。
特に、加飾シートとして通気性を有する布製又は織物製シートを用いれば、凹んだ部位の空気が加飾シートを通って逃がされるので、気泡が形成されることもない。
通気性を有しない加飾シートの場合は、たとえば左右片端側から他端側へ向かって気泡を逃がしながら徐々に液面に接触させれば気泡が形成されることがない。
The decorative layer first poured a transparent surface-side encapsulating resin that encapsulates the surface side of the decorative sheet onto the clear coat layer, and the decorative sheet is placed on the liquid surface before the resin loses its fluidity. Put.
As a result, the surface side of the decorative sheet is in contact with the liquid resin, and even if soft unevenness is formed on the decorative sheet, the unevenness is not crushed, and the resin enters the recessed portion, and the surface side is The liquid phase will be sealed.
In particular, if a cloth or woven fabric sheet having air permeability is used as the decorative sheet, air in the recessed portion is released through the decorative sheet, so that no bubbles are formed.
In the case of a decorative sheet that does not have air permeability, for example, bubbles are not formed if the bubbles are gradually brought into contact with the liquid surface while releasing the bubbles from the left and right ends to the other end.

次いで、載置された加飾シートの上に当該加飾シートの裏面側を封入する裏面側封入樹脂を流し入れると、液状樹脂が加飾シートの裏面に広がり、凹凸が形成されていてもその凹んだ部位にまで入り込むので、裏面側が液相封入されることとなる。
裏面側封入樹脂は、表面側封入樹脂が流動性のあるうちに流し入れる場合であっても、流動性のなくなった後に流し入れる場合であってもよい。
このように、加飾シートの表面側及び裏面側の双方とも液相状態の樹脂と接するので、加飾シートが破れたり、隙間が形成されることなく、また、加飾シートの凹凸や風合を損なうことがない。
Next, when the back side encapsulating resin that encloses the back side of the decorative sheet is poured onto the placed decorative sheet, the liquid resin spreads on the back side of the decorative sheet, and even if irregularities are formed, the depression Since it penetrates to the part, the back side will be sealed in a liquid phase.
The back side encapsulating resin may be poured while the front side encapsulating resin is fluid or may be poured after the fluidity is lost.
Thus, since both the front side and the back side of the decorative sheet are in contact with the resin in the liquid phase state, the decorative sheet is not torn or gaps are formed, and the unevenness and texture of the decorative sheet are also reduced. Will not be damaged.

そして、加飾層を形成する透明樹脂の流動性を消失させる予備硬化を行った後、加飾層の上に少なくとも一層のFRP層を積層成形する。
このとき、加飾層に圧力が作用したとしても、加飾シートは硬化した加飾層内に保持されているので、その圧力で加飾シートが破れたり、凹凸が潰されることがない。
したがって、加飾シートとして、表面に柔らかな凹凸のある西陣織のような高級素材を用いた場合でも、織地の凹凸や風合が損なわれず、加飾シートの意匠を十分に生かすことができる。
And after performing the preliminary hardening which lose | disappears the fluidity | liquidity of the transparent resin which forms a decoration layer, at least 1 layer of FRP layer is laminated-molded on a decoration layer.
At this time, even if pressure acts on the decorative layer, the decorative sheet is held in the cured decorative layer, so that the decorative sheet is not torn or the unevenness is not crushed by the pressure.
Therefore, even when a high-grade material such as Nishijin weave having soft unevenness on the surface is used as the decorative sheet, the unevenness and texture of the texture are not impaired, and the design of the decorative sheet can be fully utilized.

その後、所定時間放置し、あるいは、加熱してFRP層を硬化させた後、FRP成形品を型から外して完成する。
このFRP成形品は表層に形成されたクリアコート層と、FRP層の間に、透明樹脂で形成される加飾層があり、その加飾層の中間に、凹凸などが潰されることなく加飾シートが浮いた状態で保持されているので、見た目にも美しく、高級感のあるFRP成形品を製造することができる。
なお、クリアコート層は必要に応じて形成され、クリアコート層がない場合であっても、透明樹脂で形成される加飾層の中間に加飾シートが浮いた状態に保持されているので、同様の高級感を呈する。
Thereafter, the FRP layer is left for a predetermined time or heated to cure the FRP layer, and then the FRP molded product is removed from the mold to complete.
This FRP molded product has a decorative layer formed of a transparent resin between the clear coat layer formed on the surface layer and the FRP layer, and the decorative layer is decorated without being crushed in the middle of the decorative layer. Since the sheet is held in a floating state, it is possible to produce a high-quality FRP molded product that is beautiful to the eye.
In addition, the clear coat layer is formed as necessary, even if there is no clear coat layer, because the decorative sheet is held in the middle of the decorative layer formed of a transparent resin, It shows the same luxury.

本発明に係るFRP成形品の製造方法により製造されるFRP成形品1は、図4に示すように、基材となるFRP層2の表面側に、加飾シートSが封入された加飾層3が形成され、さらにその表面に、透明のクリアコート層4が形成されている。
すなわち、表層側に形成される加飾層3内に、加飾シートSが封入されている。
The FRP molded product 1 manufactured by the method for manufacturing an FRP molded product according to the present invention has a decorative layer in which a decorative sheet S is enclosed on the surface side of the FRP layer 2 serving as a base as shown in FIG. 3 is formed, and a transparent clear coat layer 4 is formed on the surface.
That is, the decorating sheet S is enclosed in the decorating layer 3 formed on the surface layer side.

このFRP成形品1は、図3に示すように、FRP成形品1の表面形状を模る型5の型表面5aに、成形品1の最表層となるクリアコート層4側から基材となるFRP層2側に向かって順次必要な素材を塗り重ねて積層するハンドレイアップ法(HLU法)により製造される。
この場合、FRP成形品1の表側が下向きに、裏側が上向きになるように各層が積層されていく。
具体的な工程は以下の通りである。
As shown in FIG. 3, the FRP molded product 1 is a base material from the side of the clear coat layer 4 that is the outermost layer of the molded product 1 on the mold surface 5 a of the mold 5 imitating the surface shape of the FRP molded product 1. Manufactured by a hand lay-up method (HLU method) in which necessary materials are successively applied and laminated toward the FRP layer 2 side.
In this case, the layers are laminated so that the front side of the FRP molded product 1 faces downward and the back side faces upward.
The specific process is as follows.

<クリアコート層形成工程>
まず、型5の型表面5aに離型剤6(図3参照)を塗布した後、図1(a)に示すように、クリアコート層4を形成するため熱硬化性の硬質透明樹脂材料やガラス材料を流し込む。
このクリアコート層4は、加飾層3を保護するものとなるから、硬化したときに加飾層3より硬質の素材を用いることが好ましい。
そして、クリアコート層4の流動性がある程度消失され、あるいは、完全に硬化された後、加飾層形成工程に移行する。
<Clear coat layer formation process>
First, after a mold release agent 6 (see FIG. 3) is applied to the mold surface 5a of the mold 5, as shown in FIG. 1 (a), in order to form the clear coat layer 4, a thermosetting hard transparent resin material or Pour glass material.
Since this clear coat layer 4 protects the decorative layer 3, it is preferable to use a material harder than the decorative layer 3 when cured.
And after the fluidity | liquidity of the clearcoat layer 4 lose | disappears to some extent or it hardens | cures completely, it transfers to a decoration layer formation process.

<加飾層形成工程>
加飾層形成工程では、図1(b)に示すように、クリアコート層形成工程で形成したクリアコート層4の上に加飾シートSの表面側を封入する透明の表面側封入樹脂7を流し入れる。
次いで、図1(c)に示すように、樹脂7が流動性を消失する前に、その液面7aに凹凸のある加飾シートSを載置する。
加飾シートSとしては、通気性を有する布製又は織物製シートが用いられ、本例では、フラットな織地部分と膨れ織された模様部分で凹凸が形成され、これらが組み合わされて高級感のある複雑な意匠を有する西陣織を用いた。
なお、加飾シートSは、通気性が高ければ、液面7aとの間に気泡が残りにくいというメリットがあるが、通気性が低い場合であっても、加飾シートSを液面7aの上方に持ち上げた状態から、その左右方端側又は前後方端側を液面7aに接触させ、他端側へ向かって気泡を逃がすように液面7aに接触させていけば、加飾シートSの表面側に凹凸が形成されていても気泡を残さずに、液面7aに載置できる。
<Decoration layer formation process>
In the decoration layer forming step, as shown in FIG. 1B, a transparent surface side encapsulating resin 7 that encapsulates the surface side of the decoration sheet S on the clear coat layer 4 formed in the clear coat layer forming step is provided. Pour.
Next, as shown in FIG. 1C, before the resin 7 loses its fluidity, the decorative sheet S with unevenness is placed on the liquid surface 7a.
As the decorative sheet S, a fabric or woven fabric sheet having air permeability is used, and in this example, irregularities are formed by a flat woven portion and a swollen pattern portion, and these are combined to give a high-class feeling. A Nishijin fabric with a complicated design was used.
The decorative sheet S has a merit that air bubbles hardly remain between the liquid surface 7a if the air permeability is high. However, even if the air permeability is low, the decorative sheet S is formed on the liquid surface 7a. If the left and right end sides or the front and rear end sides are brought into contact with the liquid level 7a from the state of being lifted upward, the decorative sheet S is brought into contact with the liquid level 7a so as to release bubbles toward the other end side. Even if irregularities are formed on the surface side, the liquid can be placed on the liquid surface 7a without leaving bubbles.

その後、図1(d)に示すように、載置された加飾シートSの上に当該加飾シートSの裏面側を封入する透明の裏面側封入樹脂8を流し入れる。
本例では、裏面側封入樹脂8は、表面側封入樹脂7と同一素材が用いられており、したがって、表面側封入樹脂7が流動性を消失していないときに裏面側封入樹脂8を流し入れても、完全に硬化した後に流し入れてもよい。
Then, as shown in FIG.1 (d), the transparent back surface side sealing resin 8 which encloses the back surface side of the said decoration sheet S on the placed decoration sheet S is poured.
In this example, the back side encapsulating resin 8 is made of the same material as the front side encapsulating resin 7, and therefore the back side encapsulating resin 8 is poured when the front side encapsulating resin 7 has not lost its fluidity. Alternatively, it may be poured after completely cured.

このようにして、凹凸のある加飾シートSを表面側封入樹脂7と裏面側封入樹脂8の間に封入した加飾層3が形成されるが、加飾シートSはその表面側が液相状態の表面側封入樹脂7に接して封入され、表面側封入樹脂7が硬化した後、あるいは、流動性を有したままの状態で、裏面側が液相状態の裏面側封入樹脂7に接して封入されることとなる。
したがって、夫々の樹脂7、8は加飾シートSの表裏に接する時点で液相であるので、加飾シートSと樹脂7、8の間に隙間が形成されることがなく、また、膨れ織等により形成された加飾シートSの凸部Bが、加飾層3を形成する際につぶれることがない。
なお、夫々の封入樹脂7、8は、熱硬化性樹脂であることが望ましい。
Thus, although the decoration layer 3 which enclosed the uneven decorative sheet S between the front surface side encapsulating resin 7 and the back surface side encapsulating resin 8 is formed, the front surface side of the decorative sheet S is in a liquid phase state. After the surface-side encapsulating resin 7 is cured, or with the fluidity maintained, the back side is encapsulated in contact with the back-side encapsulating resin 7 in a liquid phase state. The Rukoto.
Therefore, since each resin 7 and 8 is a liquid phase at the time of contacting the front and back of the decorating sheet S, a gap is not formed between the decorating sheet S and the resins 7 and 8, and the swollen weave The convex part B of the decorative sheet S formed by the above method is not crushed when the decorative layer 3 is formed.
Each encapsulating resin 7 and 8 is preferably a thermosetting resin.

<予備硬化工程>
加飾層形成工程が終了すると、室温で所定時間放置あるいは所定温度で所定時間加熱することにより、表面側封入樹脂7及び裏面側封入樹脂8の流動性を消失させる予備硬化工程を行う。
なお、表面側封入樹脂7が既に硬化されている場合は、裏面側封入樹脂8が流動性を消失し、表面側封入樹脂7が未だ硬化されていない場合は、双方の樹脂7、8が流動性を消失するまで硬化させる。
<Precuring process>
When the decorative layer forming step is completed, a pre-curing step is performed in which the fluidity of the front surface side encapsulating resin 7 and the back surface side encapsulating resin 8 is lost by being left at room temperature for a predetermined time or heated at a predetermined temperature for a predetermined time.
When the front side encapsulating resin 7 is already cured, the back side encapsulating resin 8 loses fluidity, and when the front side encapsulating resin 7 is not yet cured, both the resins 7 and 8 flow. Cured until properties disappear.

これにより、図1(e)に示すように、加飾層3は、加飾シートSが夫々の封入樹脂7、8に封入された状態に硬化される。
加飾層3は、液相の表面側封入樹脂7の上に凹凸のある加飾シートSを載置し、さらに加飾シートSの上に液相の裏面側封入樹脂8を流し入れて硬化させているので、図2に示すように、フラットな織地部分Fは、表側封入樹脂7と裏面側封入樹脂8で隙間なく挟まれ、膨れ織された模様部分などの凸部Bは、表側封入樹脂7と裏面側封入樹脂8の間に当該凸部Bに応じた形状に形成されるキャビティ9の内面に密着した状態で封入される。
したがって、膨れ織などにより形成された加飾シートSの凸部Bは、キャビティ9内に封入されることとなるので、この状態で加飾層3が加圧されても、その凸部Bがつぶれることがない。
Thereby, as shown in FIG.1 (e), the decorating layer 3 is hardened | cured in the state by which the decorating sheet S was enclosed with each encapsulating resin 7 and 8. FIG.
The decorative layer 3 has a concave and convex decorative sheet S placed on the liquid phase front side encapsulating resin 7, and the liquid phase back side encapsulating resin 8 is poured onto the decorative sheet S and cured. Therefore, as shown in FIG. 2, the flat woven portion F is sandwiched between the front-side encapsulating resin 7 and the back-side encapsulating resin 8 without a gap, and the convex portions B such as the swollen woven pattern portion are the front-side encapsulating resin. 7 and the back side encapsulating resin 8 are encapsulated in close contact with the inner surface of the cavity 9 formed in a shape corresponding to the convex portion B.
Therefore, since the convex part B of the decorative sheet S formed by the swollen weave is enclosed in the cavity 9, even if the decorative layer 3 is pressurized in this state, the convex part B is not There is no collapse.

<FRP層形成工程>
予備硬化工程が終了すると、図1(f)に示すように、流動性が消失された加飾層3の上に少なくとも一層のFRP層2を積層成形する。
FRP層2は、未硬化状態のFRPを加飾層3の上に塗り重ねる。
また、複数のFRP層2を積層形成する場合は、FRPを所定厚さに塗っては硬化させを繰り返すことにより予め設定した厚さまで積層すればよい。
FRP層2を形成する際に、加飾層3に圧力がかかっても、加飾シートSの凸部Bはキャビティ9内に封入されているので、潰されることはない。
なお、FRPは樹脂を繊維強化した従来公知の素材が用いられ、例えば、樹脂成分としては公知の熱硬化性樹脂や熱可塑性樹脂が用いられ、強化繊維としては、ガラス繊維、カーボン繊維、アラミド繊維、天然繊維などが用いられる。
<FRP layer forming step>
When the preliminary curing step is completed, as shown in FIG. 1 (f), at least one FRP layer 2 is laminated and formed on the decorative layer 3 whose fluidity has been lost.
The FRP layer 2 coats the uncured FRP on the decorative layer 3.
When a plurality of FRP layers 2 are laminated and formed, the FRP may be laminated to a predetermined thickness by repeatedly applying FRP to a predetermined thickness and curing.
Even when pressure is applied to the decorative layer 3 when the FRP layer 2 is formed, the convex portion B of the decorative sheet S is enclosed in the cavity 9 and thus is not crushed.
The FRP uses a conventionally known material in which a resin is fiber reinforced. For example, a known thermosetting resin or thermoplastic resin is used as the resin component, and the reinforcing fiber includes glass fiber, carbon fiber, or aramid fiber. Natural fibers are used.

<成形品硬化工程>
最後に、FRP層形成工程が完了した後、FRP成形品1を放置あるいは加熱して硬化させる成形品硬化工程を行う。
本例では、1日程自然放置(自然硬化)させた後、55〜100℃で30〜60分程度加熱するアフターキュアを行い、その後、型5からFRP成形品1を取り出すと、図4に示すような構造のFRP成形品1が完成する。
<Molded product curing process>
Finally, after the FRP layer forming step is completed, a molded product curing step is performed in which the FRP molded product 1 is left or heated to be cured.
In this example, after being left to stand for one day (natural curing), after-curing is performed by heating at 55 to 100 ° C. for about 30 to 60 minutes, and then the FRP molded product 1 is taken out from the mold 5 and shown in FIG. The FRP molded product 1 having such a structure is completed.

本例により、製造されるFRP成形品11は、図7に示すように、基材となるFRP層2の表面側に、加飾シートSが封入された加飾層3が形成されており、実施例1の成形品1と異なり、最表面側にクリアコート層4が形成されていない。   According to this example, as shown in FIG. 7, the manufactured FRP molded product 11 has a decorative layer 3 in which a decorative sheet S is encapsulated on the surface side of the FRP layer 2 serving as a base material. Unlike the molded article 1 of Example 1, the clear coat layer 4 is not formed on the outermost surface side.

このFRP成形品11は、図6に示すように、FRP成形品11の表面形状を模る型5の型表面5aに、成形品1の加飾層3側から基材となるFRP層2側に向かって順次必要な素材を塗り重ねて積層するハンドレイアップ法(HLU法)により製造される。
この場合、FRP成形品11の表側が下向きに、裏側が上向きになるように各層が積層されていく。
具体的な工程は、クリアコート層形成工程がないことを除き、基本的に実施例1と同様である。
As shown in FIG. 6, the FRP molded product 11 is formed on the mold surface 5 a of the mold 5 imitating the surface shape of the FRP molded product 11 from the decorative layer 3 side of the molded product 1 to the FRP layer 2 side. Are manufactured by a hand lay-up method (HLU method) in which necessary materials are sequentially applied and laminated.
In this case, the layers are laminated so that the front side of the FRP molded product 11 faces downward and the back side faces upward.
The specific process is basically the same as that of Example 1 except that there is no clear coat layer forming process.

<加飾層形成工程>
まず、型5の型表面5aに離型剤6(図6参照)を塗布した後、図5(a)に示すように、加飾シートSの表面側を封入する透明の表面側封入樹脂7を流し入れる。
次いで、図5(b)に示すように、樹脂7が流動性を消失する前に、その液面7aに凹凸のある加飾シートSを載置する。
その後、図5(c)に示すように、載置された加飾シートSの上に当該加飾シートSの裏面側を封入する透明の裏面側封入樹脂8を流し入れる。
本例では、裏面側封入樹脂8は、表面側封入樹脂7と同一素材が用いられており、したがって、表面側封入樹脂7が流動性を消失していないときに裏面側封入樹脂8を流し入れても、完全に硬化した後に流し入れてもよい。
<Decoration layer formation process>
First, after applying the release agent 6 (see FIG. 6) to the mold surface 5a of the mold 5, as shown in FIG. 5 (a), the transparent surface-side encapsulating resin 7 encapsulating the surface side of the decorative sheet S is used. Pour in.
Next, as shown in FIG. 5B, before the resin 7 loses its fluidity, the decorative sheet S with unevenness is placed on the liquid surface 7a.
Then, as shown in FIG.5 (c), the transparent back surface side sealing resin 8 which encloses the back surface side of the said decoration sheet S is poured on the placed decoration sheet S. As shown in FIG.
In this example, the back side encapsulating resin 8 is made of the same material as the front side encapsulating resin 7, and therefore the back side encapsulating resin 8 is poured when the front side encapsulating resin 7 has not lost its fluidity. Alternatively, it may be poured after completely cured.

<予備硬化工程>
加飾層形成工程が終了すると、室温で所定時間放置あるいは所定温度で所定時間加熱することにより、表面側封入樹脂7及び裏面側封入樹脂8の流動性を消失させる予備硬化工程を行う。
なお、表面側封入樹脂7が既に硬化されている場合は、裏面側封入樹脂8が流動性を消失し、表面側封入樹脂7が未だ硬化されていない場合は、双方の樹脂7、8が流動性を消失するまで硬化させる。
これにより、図5(d)に示すように、加飾層3は、加飾シートSが夫々の封入樹脂7、8に封入された状態に硬化される。
<Precuring process>
When the decorative layer forming step is completed, a pre-curing step is performed in which the fluidity of the front surface side encapsulating resin 7 and the back surface side encapsulating resin 8 is lost by being left at room temperature for a predetermined time or heated at a predetermined temperature for a predetermined time.
When the front side encapsulating resin 7 is already cured, the back side encapsulating resin 8 loses fluidity, and when the front side encapsulating resin 7 is not yet cured, both the resins 7 and 8 flow. Cured until properties disappear.
Thereby, as shown in FIG.5 (d), the decorating layer 3 is hardened | cured in the state by which the decorating sheet S was enclosed with each encapsulating resin 7 and 8. FIG.

<FRP層形成工程>
予備硬化工程が終了すると、図5(e)に示すように、流動性が消失された加飾層3の上に少なくとも一層のFRP層2を積層成形する。
FRP層2を形成する際に、加飾層3に圧力がかかっても、加飾シートSの凸部Bはキャビティ9内に封入されているので、潰されることはない。
<FRP layer forming step>
When the pre-curing step is finished, as shown in FIG. 5E, at least one FRP layer 2 is laminated and formed on the decorative layer 3 whose fluidity has been lost.
Even when pressure is applied to the decorative layer 3 when the FRP layer 2 is formed, the convex portion B of the decorative sheet S is enclosed in the cavity 9 and thus is not crushed.

<成形品硬化工程>
最後に、FRP層形成工程が完了した後、FRP成形品11を放置あるいは加熱して硬化させる成形品硬化工程を行う。
本例では、1日程自然放置(自然硬化)させた後、55〜100℃で30〜60分程度加熱するアフターキュアを行い、その後、型5からFRP成形品1を取り出すと、図7に示すような構造のFRP成形品11が完成する。
<Molded product curing process>
Finally, after the FRP layer forming step is completed, a molded product curing step is performed in which the FRP molded product 11 is left standing or heated to be cured.
In this example, after leaving it to stand naturally (natural curing) for about one day, after-curing is performed at 55 to 100 ° C. for about 30 to 60 minutes, and then the FRP molded product 1 is taken out from the mold 5 as shown in FIG. The FRP molded product 11 having such a structure is completed.

本例でも、加飾層3を形成する夫々の樹脂7、8は加飾シートSの表裏に接する時点で液相であるので、加飾層形成時に、加飾シートSと樹脂7、8の間に隙間が形成されたり、膨れ織等により形成された加飾シートSの凸部Bがつぶれることがない。
さらに、膨れ織された模様部分などの凸部Bは、表側封入樹脂7と裏面側封入樹脂8の間に当該凸部Bに応じた形状に形成されるキャビティ9の内面に密着した状態で封入される(図2参照)ので、FRP層形成工程で加飾層3が加圧されても、その凸部Bがつぶれることがない。
Also in this example, since each resin 7 and 8 which forms the decorating layer 3 is a liquid phase at the time of contacting the front and back of the decorating sheet S, at the time of decorating layer formation, the decorating sheet S and resin 7 and 8 A gap is not formed between them, and the convex part B of the decorative sheet S formed by a swollen weaving or the like is not crushed.
Further, the convex portion B such as a bulging woven pattern portion is enclosed in a state of being in close contact with the inner surface of the cavity 9 formed in a shape corresponding to the convex portion B between the front side encapsulating resin 7 and the back side encapsulating resin 8. Therefore, even if the decorative layer 3 is pressurized in the FRP layer forming step, the convex portion B is not crushed.

なお、いずれの実施例でも凹凸のある加飾シートSを用いた場合について説明したが、凹凸のないフラットな着色模様シートや金箔などを用いてもよい。
この場合も、加飾層形成工程において加飾シートSの表面側及び裏面側とも液相状態の樹脂に接するので、加飾シートSと樹脂の間に隙間が形成されることがない。
また、加飾層3が硬化された後は、加飾層3に圧力が作用しても、加飾シートSは硬化された封入樹脂7、8に保護されているので、加飾シートが破れることがない。
In addition, although the case where the decoration sheet | seat S with an unevenness | corrugation was used was demonstrated in any Example, you may use a flat coloring pattern sheet | seat, gold | metal foil, etc. without an unevenness | corrugation.
Also in this case, since the front surface side and the back surface side of the decorative sheet S are in contact with the resin in the liquid phase in the decorative layer forming step, no gap is formed between the decorative sheet S and the resin.
In addition, after the decoration layer 3 is cured, the decoration sheet S is protected by the cured encapsulating resins 7 and 8 even if pressure is applied to the decoration layer 3, so the decoration sheet is broken. There is nothing.

本発明は、加飾シートを加飾層に封入するFRP成形品を製造する用途に適用し得る。   The present invention can be applied to an application for manufacturing an FRP molded article in which a decorative sheet is enclosed in a decorative layer.

1、11 FRP成形品
2 FRP層
S 加飾シート
3 加飾層
4 クリアコート層
7 表面側封入樹脂
7a 液面
8 裏面側封入樹脂






DESCRIPTION OF SYMBOLS 1, 11 FRP molded product 2 FRP layer S Decorating sheet 3 Decorating layer 4 Clear coat layer 7 Surface side encapsulation resin 7a Liquid surface 8 Back side encapsulation resin






Claims (7)

表層側に形成される加飾層内に加飾シートを封入するFRP成形品の製造方法において、
前記成形品の表面形状を模る型表面に、当該成形品の表層となる透明なクリアコート層を形成するクリアコート層形成工程と、
クリアコート層の上に加飾シートの表面側を封入する透明の表面側封入樹脂を流し入れ、当該樹脂が流動性を消失する前にその液面に加飾シートを載置し、載置された加飾シートの上に当該加飾シートの裏面側を封入する透明の裏面側封入樹脂を流し入れて、前記加飾シートを液相内に封入した加飾層を形成する加飾層形成工程と、
前記加飾層形成工程で流し入れた透明樹脂の流動性を消失させる予備硬化工程と、
前記予備硬化工程で流動性が消失された加飾層の上に少なくとも一層のFRP層を積層成形するFRP層形成工程と、
FRP層形成工程が完了した成形品を放置あるいは加熱して硬化させる成形品硬化工程と、
を備えたことを特徴とするFRP成形品の製造方法。
In the manufacturing method of the FRP molded product in which the decorative sheet is enclosed in the decorative layer formed on the surface layer side,
A clear coat layer forming step of forming a transparent clear coat layer to be a surface layer of the molded product on the mold surface imitating the surface shape of the molded product;
A transparent surface-side encapsulating resin that encapsulates the surface side of the decorative sheet is poured onto the clear coat layer, and the decorative sheet is placed on the liquid surface before the resin loses fluidity. A decorative layer forming step of forming a decorative layer in which a transparent back side encapsulating resin encapsulating the back side of the decorative sheet is poured on the decorative sheet and the decorative sheet is enclosed in a liquid phase;
A pre-curing step for eliminating the fluidity of the transparent resin poured in the decorative layer forming step;
An FRP layer forming step of laminating and forming at least one FRP layer on the decorative layer whose fluidity has been lost in the preliminary curing step;
A molded product curing step in which the molded product in which the FRP layer forming process is completed is left or heated to be cured;
The manufacturing method of the FRP molded article characterized by having provided.
表層側に形成される加飾層内に加飾シートを封入するFRP成形品の製造方法において、
前記成形品の表層となる加飾層を形成するために、当該成形品の表面形状を模る型表面に、加飾シートの表面側を封入する透明の表面側封入樹脂を流し入れ、当該樹脂が流動性を消失する前にその液面に加飾シートを載置し、載置された加飾シートの上に当該加飾シートの裏面側を封入する透明の裏面側封入樹脂を流し入れて、前記加飾シートを液相内に封入した加飾層を形成する加飾層形成工程と、
前記加飾層形成工程で流し入れた透明樹脂の流動性を消失させる予備硬化工程と、
前記予備硬化工程で流動性が消失された加飾層の上に少なくとも一層のFRP層を積層成形するFRP層形成工程と、
FRP層形成工程が完了した成形品を放置あるいは加熱して硬化させる成形品硬化工程と、
を備えたことを特徴とするFRP成形品の製造方法。
In the manufacturing method of the FRP molded product in which the decorative sheet is enclosed in the decorative layer formed on the surface layer side,
In order to form a decorative layer that is a surface layer of the molded product, a transparent surface-side encapsulating resin that encapsulates the surface side of the decorative sheet is poured into a mold surface that imitates the surface shape of the molded product, Place the decorative sheet on the liquid surface before disappearing the fluidity, poured the transparent back side encapsulating resin encapsulating the back side of the decorative sheet on the placed decorative sheet, A decorative layer forming step of forming a decorative layer in which the decorative sheet is enclosed in the liquid phase;
A pre-curing step for eliminating the fluidity of the transparent resin poured in the decorative layer forming step;
An FRP layer forming step of laminating and forming at least one FRP layer on the decorative layer whose fluidity has been lost in the preliminary curing step;
A molded product curing step in which the molded product in which the FRP layer forming process is completed is left or heated to be cured;
The manufacturing method of the FRP molded article characterized by having provided.
前記加飾層形成工程において、表面側封入樹脂層の液面に加飾シートを載置し、当該樹脂層が流動性を消失した後、裏面側封入樹脂層を流し入れる請求項1又は2記載のFRP成形品の製造方法。   The said decoration layer formation process WHEREIN: A decoration sheet | seat is mounted in the liquid level of the surface side encapsulating resin layer, and after the said resin layer lose | disappears fluidity | liquidity, the back surface side encapsulating resin layer is poured. Manufacturing method of FRP molded product. 前記加飾シートとして通気性を有する布製又は織物製シートを用いた請求項1〜3いずれか記載のFRP成形品の製造方法。   The manufacturing method of the FRP molded product in any one of Claims 1-3 using the cloth-made or textile-made sheet | seat which has air permeability as the said decorating sheet. 前記加飾シートとして西陣織を用いた請求項1〜3いずれか記載のFRP成形品の製造方法。   The manufacturing method of the FRP molded product in any one of Claims 1-3 which used Nishijin fabric as the said decorating sheet. 前記クリアコート層形成工程において、型表面に離型剤を塗布した後、クリアコート層となる透明樹脂材料又はガラス材料を塗布する請求項1記載のFRP成形品の製造方法。   The manufacturing method of the FRP molded article of Claim 1 which apply | coats the transparent resin material or glass material used as a clearcoat layer, after apply | coating a mold release agent to the type | mold surface in the said clearcoat layer formation process. 前記加飾層形成工程において、型表面に離型剤を塗布した後、表面側封入樹脂を流し入れる請求項2記載のFRP成形品の製造方法。


The method for producing an FRP molded product according to claim 2, wherein, in the decorative layer forming step, a surface-side encapsulating resin is poured after a release agent is applied to the mold surface.


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