JP3610921B2 - Fiber-reinforced plastic molded product and method for producing the same - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a fiber reinforced plastic molded article and a method for producing the same, and in particular, a fiber reinforced plastic molded article having a rough surface, which can prevent dazzling due to reflection of sunlight or the like, and can be easily molded. The present invention relates to a method for producing a fiber-reinforced plastic molded product.
[0002]
[Prior art]
Conventionally, a fiber-reinforced plastic molded product has generally been made to have a smooth glossy surface by taking advantage of features such as easy formation of complex curved surfaces. Even when a rough surface with unevenness is formed, it relies on a method such as forming an uneven surface by coating after molding, and the unevenness of the formed uneven surface is shallow and the pattern is regular. In general, it is a thing with a periodicity.
[0003]
Recently, the use of fiber reinforced plastic molding has expanded, and it has come to be used in the field of construction and civil engineering, such as the installation of large-area molded products outdoors. In such a case, reflection of sunlight or the like may cause glare to passers-by and neighbors. As described above, for example, even if an uneven surface is formed by painting after molding, the uneven height (depth) of the uneven surface that can be formed by coating is limited, and only shallow unevenness can be formed. It was insufficient as anti-glare performance by antireflection. In addition, since the uneven surface to be formed is mostly regular or periodic, the irregular reflection performance of sunlight and the like is insufficient, and this surface is also unsatisfactory as a dazzling prevention performance. It was enough.
[0004]
[Problems to be solved by the invention]
Accordingly, an object of the present invention is to provide a fiber-reinforced plastic molded article that eliminates the above-described problems and does not give glare due to reflection even with respect to incidence of sunlight or the like, and a method for manufacturing the same. .
[0005]
[Means for Solving the Problems]
In order to solve the above-mentioned problems, at least one surface of the fiber-reinforced plastic molded article according to the present invention is an uneven surface in which convex portions and concave portions are randomly arranged, and the average height of convex portions and concave portions. A fiber reinforced plastic molded product formed on a rough surface having a difference of 0.5 mm or more, wherein the fiber reinforced plastic forming the rough surface is at least a layer intended to form a rough surface; It is composed of two layers including a layer for the purpose of obtaining strength and rigidity .
[0006]
The rough surface with the difference in height between the average convex portion and the concave portion of 0.5 mm or more as described above is difficult to form by the conventional coating method. In particular, such a rough surface is formed. It cannot be formed without a special method intended to do.
[0007]
Such a rough surface can constitute a light irregular reflection surface and / or a light absorption surface, and is suitable for an uneven surface in which convex portions and concave portions are randomly arranged with respect to incidence of sunlight or the like. By irregularly reflecting light and / or appropriately absorbing light, dazzling due to reflected light is effectively prevented. In other words, it is an uneven surface in which convex portions and concave portions are randomly arranged, and is a rough surface having a difference in height between the average convex portion and concave portion of 0.5 mm or more, so it is excellent in dazzling prevention. The effect is obtained.
[0008]
The fiber reinforced plastic that forms the rough surface as described above may be colored with a pigment contained in the plastic. By coloring, in addition to irregular reflection performance due to a random uneven surface shape, it is possible to have appropriate light absorption performance, and dazzling due to reflected light can be more effectively prevented.
[0009]
The fiber-reinforced plastic to form a rough surface, at least, a layer intended to form a rough surface, it that is composed of two layers of a layer for the purpose of obtaining a strength and rigidity. If comprised in this way, both the characteristics of the outstanding dazzling prevention performance made into the target by this invention are achieved satisfactorily, ensuring the target intensity | strength and rigidity easily. In addition, by separating the layer for forming the rough surface and the layer for obtaining the strength rigidity, the orientation of the reinforcing fiber for obtaining the strength rigidity does not cause local bending due to the influence of the surface unevenness. It is possible to prevent the strength rigidity from being lowered.
[0010]
Moreover, the fiber reinforced plastic which forms a rough surface can also be set as the structure which has the colored layer for the purpose of an external appearance improvement in the outermost side. Resin degradation due to ultraviolet rays is suppressed to only a small part of the surface by adopting a configuration in which the entire resin is colored by the pigment contained in the fiber reinforced plastic described above or a configuration having a colored layer in the outermost layer. And durability can be improved. Such a colored layer may be formed by any method, and can be formed, for example, by spraying paint droplets of two or more different colors.
[0011]
The fiber reinforced plastic having a multilayer structure and forming a rough surface is preferably integrally molded regardless of the number of layers constituting the rough surface. This ensures good moldability and mechanical properties of the entire fiber-reinforced plastic molded product.
[0012]
The fiber-reinforced plastic molded product according to the present invention may have a so-called sandwich structure. For example, a sandwich structure having a sandwich structure portion composed of a core material and a fiber reinforced plastic skin material positioned on both sides of the core material, wherein at least one skin material is composed of a fiber reinforced plastic molded product as described above It can be set as the fiber reinforced plastic molding which has a part. In this case, it is preferable that the core material and the fiber reinforced plastic skin material located on both sides of the core material are molded integrally, and this also improves the moldability and mechanical characteristics of the entire fiber reinforced plastic molded product. Secured.
[0013]
The method for producing a fiber-reinforced plastic molded product according to the present invention is a method of molding a fiber-reinforced plastic molded product having the above-described configuration with tics, and at least one surface has irregularities obtained by inverting the predetermined rough surface shape described above. It comprises a method characterized in that a rough surface is formed by transferring a concavo-convex surface of a mold to a molded product using a molding die having a processed surface. In this way, the difference in height between the convex portion and the concave portion can be increased by transferring the concave and convex portions of the mold and forming the concave and convex surface instead of coating afterwards.
[0014]
In this method, it is preferable that the uneven surface of the mold is formed of a material having elasticity that can follow the deformation. Since the uneven surface of the mold is formed of an elastic material, a large force is not required at the time of demolding, and the mold or molded product is not chipped. Further, in the case of a molded product having a sandwich structure as described above, the uneven surface of the mold is preferably formed of a material having a lower elastic modulus than the core material included in the molded product. As a result, even when a molding method (for example, the SCRIMP method) that requires pressure during molding is used, the unevenness of the molding die does not affect the layer for obtaining the strength and rigidity, and a phenomenon such as a decrease in strength is prevented.
[0015]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, preferred embodiments of the present invention will be described with reference to the drawings.
1 and 2 show a fiber-reinforced plastic molded article according to an embodiment of the present invention. In FIG. 1, reference numeral 1 denotes an entire fiber reinforced plastic molded article, for example, a fiber reinforced plastic molded article having a structure suitable as a soundproof wall or a partition wall. Reference numeral 2 denotes a wall body portion, and 3 denotes an attachment portion to another building or pedestal. In this embodiment, the wall main body 2 particularly has the configuration of the fiber-reinforced plastic molded product according to the present invention, and at least one surface (outer surface) thereof is an uneven surface in which convex portions and concave portions are randomly arranged. And it is formed in the rough surface 4 whose height difference of an average convex part and a recessed part is 0.5 mm or more.
[0016]
In the present embodiment, the wall main body 2 is configured as a sandwich structure composed of a core material 5 and a fiber reinforced plastic skin material 6 positioned on both sides of the core material 5, and at least the outer skin material 6. Or the layer added to the outer side is formed in the shape which has the rough surface 4. FIG. The core material 5 and the fiber reinforced plastic skin material 6 positioned on both sides of the core material 5 are integrally formed. Although the material of the core material 5 is not particularly limited, it is preferable to have a specific gravity or an apparent specific gravity as small as possible while having desired strength and rigidity from the viewpoint of ensuring the light weight as a whole. For example, a foam (for example, rigid foam polyurethane), wood, a honeycomb structure, or the like can be used.
[0017]
In the present embodiment, the fiber reinforced plastic layer forming the rough surface 4 is intended to obtain at least a layer 7 intended to form the rough surface 4 and strength and rigidity as shown in FIG. The colored layer 9 is provided on the outer side (outermost layer) of the layer 7 for the purpose of mainly improving the appearance and also having the ability to prevent resin deterioration due to ultraviolet rays. .
[0018]
The layer 8 for the purpose of obtaining strength and rigidity is composed of a layer containing reinforcing fibers in one direction, two directions, a woven fabric or the like, for example, and the layer 7 for the purpose of forming the rough surface 4 includes: For example, it is composed of a layer including a mat of reinforcing fibers, and the colored layer 9 is composed of, for example, a gel coat layer of two or more colors, a pigment-containing resin layer, or the like. A colored layer of two or more colors can be formed by spraying paint droplets of two or more different colors using, for example, an air gun. The type of the reinforcing fiber is not particularly limited, and can be appropriately selected from carbon fiber, glass fiber, aramid fiber, unsaturated polyester fiber, inorganic fiber, and the like, and can be used in combination. The type of the matrix resin is not particularly limited, and a thermoplastic resin can be used in addition to a thermosetting resin such as an epoxy resin, a vinyl ester resin, or a phenol resin.
[0019]
In order to form the rough surface 4 in which the convex portion and the concave portion are randomly arranged, and the difference in height between the average convex portion and the concave portion is 0.5 mm or more, the rough surface 4 It is preferable to mold using a mold having an uneven surface whose shape is inverted. In the conventional method by painting, it is difficult to form a rough surface having the unevenness depth defined in the present invention. By transferring the uneven surface of the mold to the molded product, a rough surface having the uneven surface depth defined in the present invention can be easily formed.
[0020]
The concave / convex surface of the mold is preferably formed of a material having elasticity that can follow the deformation particularly during demolding. As such a concave / convex surface forming material, for example, urethane rubber having a relatively low hardness, etc. Can be used. Further, when the core material 5 is included in the molded product as described above, it is preferable that the core material 5 is formed of a material having a lower elastic modulus than the core material 5. By forming the uneven surface of the molding die with such a material, as described above, it is possible to prevent a large force from being required at the time of demolding and chipping of the mold or molded product, and molding at the time of demolding. It is possible to prevent adverse effects such as deformation on the product side.
[0021]
As a method for molding a fiber-reinforced plastic molded article according to the present invention, any of general fiber-reinforced plastic molding methods such as a hand lay-up method and an autoclave method can be used. Moreover, each member shape | molded by continuous molding methods, such as a pultrusion method, can also be shape | molded by an assembly joining after cut | disconnecting to a suitable dimension. However, preferably, the integral molding is easy and the fiber content is easily increased to achieve weight reduction, so-called RTM method or RIM method, or the injection resin diffusion material is disposed at the same time as the molding site is decompressed. It is desirable to adopt a molding method in which a liquid plastic is injected into a cavity in which reinforcing fibers are arranged, such as an integral molding method (SCRIMP method).
[0022]
【Example】
Hereinafter, a description will be given based on a more specific embodiment.
A fiber-reinforced plastic molded article as shown in FIGS. 1 and 2 was produced. An uneven sheet having an average depth of about 3 mm, which is formed of urethane rubber having a hardness of 60 degrees by a hardness measurement method defined in JIS-K-6301 as a mold for transferring an uneven surface. Was used to apply a silicone release material to the surface of the sheet. Thereafter, a gel coat mainly composed of a polyester resin was applied using an air gun so as to be arranged in three colors of white, black, and brown, and was once cured.
[0023]
Furthermore, for molding of the outer surface side having a rough surface, in order to form a layer for the purpose of forming the rough surface, the object is to obtain one layer of chopped strand mat of glass fiber and strength rigidity. In order to form a layer, 1 ply of 0/90 ° woven fabric of glass fiber and 1 ply of 0 ° woven fabric of carbon fiber are laminated, 30 times foamed rigid polyurethane foam is used as the core material, and it has a non-rough surface For the molding on the inner surface side, 1 ply of glass fiber 0/90 ° woven fabric was laminated in order to form a non-rough surface skin layer, and the whole was integrally molded by the aforementioned SCRIMP method. The matrix resin was an unsaturated polyester resin and was colored gray using a pigment.
[0024]
The obtained fiber reinforced plastic molded article had a design surface similar to brick, and did not reflect light in a certain direction even when exposed to direct sunlight, and could not be dazzled. . In addition, despite the use of a mold having deep irregularities, the mold release was very easy, and neither scratches nor chipping occurred in the obtained molded product or the mold after demolding.
[0025]
When the obtained fiber reinforced plastic molded product was cut and the cross section was observed, a layer intended to form a rough surface was provided immediately inside the rough surface, and thus the layer intended to obtain strength was obtained. The reinforcing fiber was kept in a substantially straight state without being affected by the uneven surface. As a result, physical properties such as tensile strength and elastic modulus could be developed as designed.
[0026]
In addition, using this molding technique, a soundproof wall for a railway viaduct having the rough surface defined in the present invention and having the form as shown in FIGS. 1 and 2 was molded and installed on the viaduct on a trial basis. Even on the side road below, there was no reflection of sunlight that felt dazzling.
[0027]
【The invention's effect】
As described above, according to the fiber-reinforced plastic molded product according to the present invention, even if direct sunlight is incident on the surface, the fiber-reinforced plastic does not give glare to a third party by irregularly reflecting it. A molded product can be obtained. That is, a fiber reinforced plastic molded product can be applied to a building or a structure that is installed outdoors.
[0028]
In addition to improving the appearance design by covering the surface with a colored layer such as a gel coat or adding a pigment to the matrix resin, the deterioration of the fiber-reinforced plastic molded product due to ultraviolet rays is minimized. Therefore, it can be made more suitable for outdoor use.
[0029]
Furthermore, by providing a layer for the purpose of forming a rough surface, the linearity of the reinforcing fibers contained in the layer for the purpose of obtaining strength and rigidity can be maintained, and as a result, the original strength and rigidity can be maintained. The surface of the fiber-reinforced plastic molded product can be made a desired rough surface without affecting the above.
[0030]
In addition, by using an elastic material that can follow large deformations for the mold that transfers the uneven surface, even if the surface has deep unevenness, a large force is required for demolding. The target molded product can be easily obtained without damaging the molded product.
[Brief description of the drawings]
FIG. 1 is a perspective view of a fiber-reinforced plastic molded product according to an embodiment of the present invention.
FIG. 2 is an enlarged cross-sectional view of a portion II in FIG.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 Fiber reinforced plastic molding 2 Wall main-body part 3 Attachment part 4 Rough surface 5 Core material 6 Fiber reinforced plastic skin material 7 Layer 8 which aims at forming a rough surface Layer 9 which aims at strength and rigidity Colored layer

Claims (11)

Fiber reinforced plastic having at least one surface formed of a rough surface in which convex portions and concave portions are randomly arranged and a difference in height between average convex portions and concave portions is 0.5 mm or more. A fiber reinforced plastic that forms a rough surface, which is a molded product, is composed of at least two layers: a layer that is intended to form a rough surface and a layer that is intended to obtain strength and rigidity. fiber-reinforced plastic molded article, characterized in that there. The fiber-reinforced plastic molded article according to claim 1, wherein the rough surface constitutes a light irregular reflection surface and / or a light absorption surface. The fiber-reinforced plastic molded article according to claim 1 or 2, wherein the fiber-reinforced plastic forming the rough surface is colored with a pigment contained in the plastic. The fiber-reinforced plastic molded article according to any one of claims 1 to 3, wherein the fiber-reinforced plastic forming the rough surface has a colored layer on the outermost side for the purpose of improving the appearance. . The fiber-reinforced plastic molded article according to claim 4 , wherein the colored layer is formed by spraying two or more kinds of paint droplets having different colors . The fiber-reinforced plastic molded article according to any one of claims 1 to 5, wherein the fiber-reinforced plastic forming the rough surface is integrally molded regardless of the number of layers constituting the rough surface . The fiber reinforced plastic molded article according to any one of claims 1 to 6, further comprising a sandwich structure composed of a core material and a fiber reinforced plastic skin material positioned on both sides of the core material. A fiber-reinforced plastic molded article having a sandwich structure part comprising: The fiber-reinforced plastic molded article having a sandwich structure according to claim 7, wherein the core material and the skin material made of fiber-reinforced plastic located on both sides of the core material are integrally molded. 9. A rough surface is formed by transferring a concave / convex surface of a mold to a molded product using a molding die having a concave / convex surface obtained by reversing a predetermined rough surface shape on at least one surface. A method for producing a fiber-reinforced plastic molded article according to any one of the above. The method for producing a fiber-reinforced plastic molded article according to claim 9, wherein the uneven surface of the mold is formed of a material having elasticity capable of following deformation . The fiber reinforced plastic molded product has a sandwich structure part composed of a core material and a fiber reinforced plastic skin material positioned on both sides of the core material, and at least one skin material is formed from the rough surface. The method for producing a fiber-reinforced plastic molded product according to claim 9 or 10 , wherein the uneven surface of the mold is formed of a material having a lower elastic modulus than the core material included in the molded product.

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