JP3072285B2 - FRP molded products - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

The present invention relates to a heat insulating layer and a support layer mainly composed of a reaction curable resin and reinforcing fibers, which are laminated on the back side of a gel coat layer mainly composed of a reaction curable resin. FRP (fiber reinforced resin) molded article.

[0002]

2. Description of the Related Art In the above-mentioned FRP molded article, for example, in order to provide a heat insulating property such as a bathtub or a water tank, the heat insulating layer is conventionally formed of a foamed resin such as polyurethane, and the heat insulating layer and the gel coat are formed. The support layer was arranged between the layers and formed integrally.

[0003]

However, although the support layer has a sufficient supporting effect on the gel coat layer, it contains reinforcing fibers as a main material in addition to the reactive curable resin. There is a problem that the gel coat layer needs to be thickened because the resin between the two shrinks during curing to become uneven, which adversely affects the surface of the gel coat layer. Therefore, an object of the present invention is to provide an FRP molded product having a smooth surface even when the thickness of a gel coat layer is reduced while maintaining heat retention in view of the above problem.

[0004]

Means for Solving the Problems As a result of intensive studies to achieve the above object, the characteristic constitution of the present invention is as follows. (Constitution 1) A reaction-curable resin containing a balloon-like lightweight filler without mixing fibers, and the reaction-curable resin having a weight of 100
20 to 100 parts by weight of the lightweight filler with respect to the
Forming said insulation layer by entering, it arranged integrally formed between the heat insulating layer and the gel coat layer and the support layer, or
In addition, the average thickness of the heat insulating layer is formed to be 2.0 to 5.0 mm.
It is in the point that has been. ( Structure 2 ) The lightweight filler is at least one selected from the group consisting of a shirasu balloon, a ceramic balloon, a glass balloon, a silica balloon, a carbon balloon, a phenol balloon, and an alumina balloon.
It has a size of ( Configuration 3 ) The reaction-curable resin is an unsaturated polyester resin, a vinyl ester resin, a bisphenol-based polyester resin,
It is a kind selected from the group of epoxy resins.

(Function 1) According to the above-mentioned configuration 1, the balloon-shaped lightweight filler exhibits heat insulating properties due to the space confined therein, and has a substantially spherical shape, so that it has a reaction hardening property. By integrating with the resin and laminating directly on the back surface of the gel coat layer, there is no adverse effect such that unevenness due to the reinforcing fiber appears on the surface of the gel coat layer unlike a conventional FRP molded product. If the lightweight filler is less than 20 parts by weight with respect to 100 parts by weight of the reaction curable resin, the heat insulating property is inferior, and if it is more than 100 parts by weight, the heat insulating layer becomes brittle. Although it is preferable in performing spray molding such as an up method, a heat insulation layer having good heat insulation and strength can be formed at 20 to 100 parts by weight in consideration of brush coating. In addition, the average thickness of the insulation layer
If it is smaller than 2.0 mm, the heat retention is inferior and 5.0 m
If it is larger than m, it takes a lot of time and effort for molding.
A thickness of 0 mm is practical, but 2.0-5.0 mm
At the average thickness, both heat retention and moldability can be improved. ( Function 2 ) According to the above configuration 2 , if the lightweight filler is at least one selected from the group consisting of a shirasu balloon, a ceramic balloon, a glass balloon, a silica balloon, a carbon balloon, a phenol balloon, and an alumina balloon, the heat insulating property is obtained. Of course, it has high strength and heat resistance. Above all, a shirasu balloon is inexpensive and has an uneven surface shape, so that it is well compatible with the reaction curable resin and has a large bonding strength, and also has a high supporting strength for the gel coat layer as in the case of the supporting layer. The size is preferably 150 μm because the heat retention is poor if the size is smaller than 10 μm, and the surface smoothness is poor if the size is larger than 300 μm.
When the thickness is 300 μm, the heat retention is large and the smoothness of the gel coat layer is not adversely affected. ( Function 3 ) According to the above configuration 3 , if the reaction curable resin is one selected from the group consisting of an unsaturated polyester resin, a vinyl ester resin, a bisphenol-based polyester resin, and an epoxy resin, heat resistance and water resistance are provided. And high strength.

(Effects of the Invention) As described above, according to the present invention, the surface can be made smooth even if the thickness of the gel coat layer is reduced while maintaining good heat retention, and the conventional urethane foam It is now possible to expect a large support strength not available with resin.

[0007]

Embodiments of the present invention will be described below. The main component is bisphenol-based polyester resin, which is a reaction curable resin, containing 0.4 mm pigment
A thick gel coat layer is formed on the front surface side, and the heat insulation layer of 3 mm thickness is formed of the bisphenol-based polyester resin mixed with a balloon-like lightweight filler without mixing fibers on the back surface side of the gel coat layer. Is further formed on the back side of the heat insulating layer, wherein an unsaturated polyester resin which is a reaction curable resin and glass fibers having a length of 25 to 30 mm as a reinforcing fiber are mainly used. An FRP bath is formed by forming a support layer having a thickness of 0 mm and integrally laminating the gel coat layer, the heat insulation layer and the support layer.

The lightweight filler has an average particle size of 150 μm.
20 to 100 parts by weight of a substantially spherical hollow shirasu balloon having a size of m with respect to 100 parts by weight of the reaction-curable resin (preferably 20 to 50 parts by weight for spray molding by a spray-up method) To ensure the heat retention. The shirasu balloon (Silax Co., Ltd., PB-03) contains silica (S) as a chemical component.
iO ₂ ) and alumina (Al ₂ O ₃ ) mainly account for 85% or more, the bulk specific gravity (kg / liter) is 0.1 to 0.5, and the moisture absorption (24 hours / weight%) is 0.08%. , Thermal conductivity (K
Cal / m, hr ° C.) 0.05-0.09, softening point (° C.) 850-1000, strength (2 minutes under hydrostatic pressure)
At 0 kg / square cm, it is nonflammable and has excellent fire resistance and heat insulation. In addition, the shirasu balloon has a good mixing property and adhesiveness with the resin, and not only the balloon absorbs heat generated when the reaction-curable resin is cured, but also bridges the resins, so that shrinkage upon cooling is reduced. Extremely small, preventing sinks and cracks and increasing the product efficiency of the resin. Furthermore,
By mixing the shirasu balloon, the resin is given thixotropy, so that no dripping occurs at the time of coating, a single coating can be made thicker, and a uniform coated surface can be obtained.

Next, the method of manufacturing the FRP bath according to the present invention will be described. First, a gel coat layer is formed on the surface of a mold, a heat insulating layer is formed on the surface of the gel coat layer, and further a heat insulating layer is formed on the surface of the heat insulating layer. A support layer is formed respectively.

Hereinafter, each step will be described in order. [Step of Forming Gel Coat Layer] The gel coat layer is formed by a known material / method mainly for the purpose of forming a beautiful surface and preventing water leakage. The outline of this step is to form a gel coat layer by applying a coating material mainly containing a reaction curable resin and a pigment by spraying or brush coating on a surface of a mold such as a mold and a resin mold, When the next step is performed after the resin is cured, the resin is cured after the application. As the reaction curable resin, an unsaturated polyester resin, a vinyl ester resin, an epoxy resin or the like is used. Also, other pigments, Ru can be used additives such as a thickener. The average thickness of the gel coat layer after curing is about 0.2 to 0.5 mm, preferably 0.1 to 0.5 mm.
3 to 0.4 mm.

[Step of Forming Heat Insulating Layer] In the step of forming the heat insulating layer, a reactive curable resin mixed with a light-weight particulate filler is sprayed onto the gel coat layer as a coating material. As the kind of the granular lightweight filler, a hollow inorganic material or a resin material can be used, but a spherical hollow body is preferably used. Specifically, shirasu balloon, ceramic balloon, glass balloon, silica balloon, carbon balloon, phenol balloon, alumina balloon and the like are used. Above all, a shirasu balloon is preferably used in the present invention because it is inexpensive and has good compatibility with resins and fibers. The average particle diameter of the lightweight filler is preferably 10 to 300 μm, and 30 to 200 μm.
Is more preferred. In other words, if it exceeds this range, not only does it become less compatible with the resin, but if it is less than 10 μm, the heat retention is poor, and if it is more than 300 μm, the smoothness after molding tends to be poor. The amount of the particulate light filler used is, based on the above-mentioned reason, based on 100 parts by weight of the reaction curable resin,
Although it is preferably 20 to 50 parts by weight, about 20 to 100 parts by weight can be used depending on the type of the resin used and the method of forming the layer. If the viscosity increases, the surface tends to be uneven, and molding by the spray-up method is difficult. However, if it exceeds 100 parts by weight, it becomes brittle.

Examples of the reactive curable resin include those containing a resin component such as an unsaturated polyester resin, a vinyl ester resin and an epoxy resin, and a monomer component such as a styrene monomer and an acrylic monomer. The viscosity of such a reaction curable resin can be adjusted by adjusting the amount of the monomer component.
Adjust to 0 poise, more preferably 14 to 40 poise. If it is less than this range, dripping tends to occur and the thickness of the layer tends to be difficult to obtain. More coating materials, wherein at blown to gelcoat layer, the average thickness of the heat insulating layer obtained by the above, from the reason described above, after curing
2 . It is more preferable that the thickness be 0 to 5.0 mm, since it is possible to secure sufficient heat retention to the gel coat layer while imparting sufficient strength.

[Step of Forming Support Layer] The support layer is formed by a known material and method mainly for the purpose of increasing the overall strength of the FRP molded product. The outline of this step is to form a support layer by applying a coating material mainly composed of a reaction-curable resin and fibers to the surface of the heat insulating layer by spraying or the like, and then curing the resin after the application. Examples of the type of fiber include glass fiber and those obtained by subjecting the fiber to various surface treatments, and any fiber having similar physical properties can be used. The average fiber length of the fiber is 15 to 50
mm, more preferably 25-30.
mm. If it exceeds this range, fluffing tends to increase, and if it is less than this range, the reinforcing effect tends to decrease. The amount of the fiber used depends on the type of the resin used, but is preferably 30 to 40% by weight based on the total weight of the support layer from the viewpoint of the strength of the support layer.

Examples of the reactive curable resin include those containing a resin component such as an unsaturated polyester resin, a vinyl ester resin, and an epoxy resin, and a monomer component such as a styrene monomer and an acrylic monomer. The viscosity of such a reaction curable resin can be adjusted by the amount of the monomer component. The coating material described above is sprayed on the back surface side of the heat insulating layer (the molding procedure is the front surface of the heat insulating layer) in the same manner as in the step of forming the heat insulating layer. The average thickness of the support layer obtained after curing is preferably about 1.5 to 2.5 mm.

The FRP molded product of the present invention is used for applications such as FRP bathtubs, water tanks, septic tanks, waterproof pans for bathrooms, etc., and the shape of the mold is determined according to their shapes.

Continued on the front page (51) Int.Cl. ⁷ Identification code FI B29K 67:00 105: 06 105: 16 461: 04 509: 00

Claims (3)

(57) [Claims] 1. An FRP molded product in which a heat insulating layer and a support layer mainly composed of a reaction curable resin and reinforcing fibers are laminated on the back side of a gel coat layer mainly composed of a reaction curable resin. There is a reaction-curable resin mixed with a balloon-like lightweight filler without mixing fibers , and the reaction-curable resin is 100 weight
20 to 100 parts by weight of the lightweight filler with respect to the
Forming said insulation layer by entering, it arranged integrally formed between the heat insulating layer and the gel coat layer and the support layer, or
In addition, the average thickness of the heat insulating layer is formed to be 2.0 to 5.0 mm.
The FRP molded products are. 2. The lightweight filler comprises a shirasu balloon,
Ceramic balloon, glass balloon, silica balloon, carbon balloon, phenol balloon, at least one selected from the group of alumina balloon,
Claim and has a size of 10 to 300 [mu] m 1
The FRP molded article according to the above. Wherein the reactive curable resin, unsaturated polyester resin, vinyl ester resin, a bisphenol type polyester resin, FRP molding according to claim 1 or 2 which is one selected from the group of epoxy resin Goods.