JP3743536B2 - FRP molded product and molding method of FRP molded product - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to an FRP molded product having a concavo-convex pattern on the surface and a continuous manufacturing method thereof by a pultrusion method.
[0002]
[Prior art]
FRP has many features such as light weight, high strength and excellent corrosion resistance, and is used in various fields such as bus units, tanks, and automobile parts. Conventionally, when a concavo-convex pattern is formed on the surface of these products, the concavo-convex pattern is transferred to the FRP surface using a molding die (mold) having a concavo-convex shape on the surface.
[0003]
However, these methods have poor productivity, and in a molded product having a standing surface portion, the uneven pattern on the standing surface portion is undercut and is difficult to form integrally. Moreover, with the conventional pultrusion method, it has been difficult to obtain a molded product with irregularities perpendicular to the drawing direction of the molded product.
[0004]
Therefore, in the pultrusion molding method, as a molding method for forming irregularities at right angles to the drawing direction of the molded product, there is an embossed pattern on one side between the layers of the resin-impregnated fiber base material drawn into the die hole, and the embossed pattern surface is An embossed pattern (uneven pattern) is formed by continuously interposing a sheet-like body that has been treated so that it can be peeled off after pultrusion molding and integrally curing with the resin-impregnated fiber base material, and then peeling the surface having the embossed pattern. A method of molding has been proposed (Japanese Patent Laid-Open No. 1-317750). However, this method requires a peeling operation of the sheet-like body after molding, and cannot be said to be a reasonable means, and is complicated in production.
[0005]
[Problems to be solved by the invention]
An object of the present invention is to provide an FRP molded product in which a concavo-convex pattern is continuously formed on the surface of a molded product at right angles to the drawing direction in the pultrusion molding method, and a molding method thereof.
[0006]
[Means for Solving the Problems]
As a result of intensive research, the inventor inserts a sheet / film material having a plurality of holes in the thickness direction between the pattern material used for the outermost layer of the FRP molded product and the FRP material, and integrally molds the same. As a result, it has been found that the above problems can be solved, and the present invention has been completed.
[0007]
That is, the present invention relates to a method in which a resin-impregnated fiber base material is drawn into a heated die and is cured while being run in the direction of the die axis, and FRP is continuously drawn and molded. Before drawing the fiber base into the die hole, a sheet or film material with multiple holes in the thickness direction is continuously stacked between the pattern material placed on the surface layer and the resin-impregnated fiber base. After forming and aligning, a molding method in which the die is drawn into a die hole and integrally cured, and an FRP molding in which a concavo-convex pattern is formed partially or entirely on one or both surface layers produced by using this molding method. Related to goods.
[0008]
DETAILED DESCRIPTION OF THE INVENTION
Next, the present invention will be described in detail.
The surface layer made of a pattern material obtained by printing a pattern on a nonwoven fabric, woven fabric or paper in advance of the present invention is a nonwoven fabric, a woven fabric or a nonwoven fabric manufactured using polyester fiber, rayon fiber, polypropylene fiber, vinylon fiber or the like. This is a layer formed by integrally molding paper with a matrix resin derived from the FRP molding material. The pattern material is obtained by printing a pattern on these non-woven fabric, woven fabric or paper in advance. This thickness is preferably 0.1 to 1.0 mm.
[0009]
The (B) sheet / film material layer having a plurality of holes in the thickness direction of the present invention is a layer in which the sheet / film material is integrally formed with a matrix resin derived from the FRP molding material. The material has a thickness of preferably 0.1 mm to 2 mm, more preferably 0.1 mm to 1 mm. The material may be an inorganic material such as glass, or an organic material such as polyertel, rayon, polypropylene, vinylon, etc. Good. Examples of forms include those obtained by punching holes in a smooth sheet / film, those obtained by weaving a thread-like material into a mesh, or those obtained by adhering a thread-like material to form a mesh-like sheet. The opening ratio of the holes is preferably 30 to 99.9%, and more preferably 70 to 99.9%.
[0010]
The (C) mat or woven fiber reinforcing material layer of the present invention is a layer in which a mat or woven fiber reinforcing material is integrally formed with a matrix resin derived from an FRP molding material, and is preferably used as a fiber reinforcing material. Glass fibers are used, but organic fibers such as carbon fibers, aramid fibers, other vinylon fibers, and polyester fibers can also be used. The mat is preferably a chopped strand mat or a swirl mat, and the woven form is preferably a roving cloth or a glass cloth. This thickness is preferably 1.0 to 10 mm.
[0011]
The (D) FRP molding material layer of the present invention is obtained by impregnating a matrix resin into a fiber reinforcement for FRP and curing it. The fiber reinforcing material for FRP used in the present invention is preferably glass fiber, but organic fibers such as carbon fiber, aramid fiber, other vinylon fiber, and polyester fiber can be used alone or in combination. Examples of the form of the fiber reinforcement include those that can be impregnated with a matrix resin and molded into a predetermined shape before curing, preferably roving, cloth, mat, and the like. These can be used alone or in combination.
[0012]
The matrix resin for FRP to be impregnated is preferably an unsaturated polyester resin, but vinyl ester resins, epoxy resins, phenol resins, acrylic resins, other thermosetting resins, etc. can be used. A compound in which a curing catalyst, an inorganic or organic filler is mixed can also be used. Moreover, you may add and color a pigment. This compound is put into an impregnation tank.
[0013]
As a filler, if only typical ones are exemplified, calcium carbonate powder, clay, alumina powder, meteorite powder, talc, barium sulfate, silica powder, glass powder, mica, aluminum hydroxide, or the like Among them, known and commonly used ones are mentioned, but in particular, the use of calcium carbonate, glass powder, aluminum hydroxide or barium sulfate is desirable.
[0014]
The pultrusion molding method of the present invention is to arrange the reinforcing fibers necessary for constituting the FRP, pass through a matrix resin impregnation tank to obtain an FRP molding material (D), on which a mat or woven fiber reinforced After stacking the material (C), the sheet / film material (B) with a plurality of holes in the thickness direction, and the pattern material (A), they are molded into a predetermined shape and heated. The FRP is continuously drawn and formed by drawing into the hole and curing while running in the direction of the die axis.
[0015]
Here, in order to improve the gloss and texture by forming a clear resin layer on the surface of the molded product, the surface layer made of (A) pattern material is an impregnation tank filled with a matrix resin impregnation tank for FRP and another matrix resin. It is also possible to superimpose after passing through and impregnating the matrix resin. Further, a matrix resin different from the matrix resin for FRP can be injected from a resin injection port provided near the entrance of the die, and the surface layer made of (A) pattern material can be impregnated with the matrix resin.
[0016]
The conditions of the pultrusion molding are preferably a die heating temperature of 40 ° C. to 180 ° C. and a drawing speed of 10 cm / min to 150 cm / min, depending on the composition of the matric resin used, the shape and size of the molded product, etc. It can be selected as appropriate.
[0017]
With the molded product of the present invention, a concavo-convex pattern is formed in order of (A) layer, (B) layer, and (C) layer on one or both sides of the molded product, or partially or entirely on the surface layer of the outer surface or inner surface. It is formed on the material layer (D). When the molded product of the present invention forms a concavo-convex pattern on both sides (inner surface and outer surface), the cross section is from the outer surface side (A) layer, (B) layer, (C) layer, molding material layer (D), ( C) layer, (B) layer, and (A) layer. When the uneven pattern is partially provided, the (A) layer, (B) layer, and (C) layer are partially formed on the (D) layer.
[0018]
The thickness of the pultruded FRP molded product is not particularly limited, but is preferably 1 to 20 mm, and particularly preferably 2 to 6 mm. The cross-sectional shape is a flat cross-sectional shape such as a flat plate, C-type, L-type, H-type, T-type, E-type, B-type, round shape, square shape, triangular shape, etc. It can be round, square, triangular, etc. or a solid bar shape with a modified cross section. This cross-sectional shape is also the cross-sectional shape of the die.
[0019]
As an application of the molded product of the present invention, the flat plate-shaped molded product can be used as a housing member such as a flooring material, a wall material, a ceiling material, a counter material, and a top plate. Pipe-shaped and bar-shaped molded products can be used as interior members such as decorative columns and handrails, and industrial members.
[0020]
【Example】
EXAMPLES Hereinafter, although an Example demonstrates this invention in detail, this invention is not limited to this.
[0021]
Example 1
A die (a) (90 cm long, plated steel die), a forming guide (b), and a matrix resin impregnation tank (c) as shown in FIG. 1 were installed in an ordinary pultrusion molding machine. Here, the die (a) has a space (x) for injecting a matrix resin inside the mold, and a structure in which a clear resin layer can be formed on the surface of the pattern material (A) by press-fitting the matrix resin into the space. Yes. Further, in order to prevent the matrix resin from hardening in the matrix resin injection space, a cooling circuit (y) is built in the vicinity of the space. The die was heated to 150 ° C., and the vicinity of the matrix resin injection space was cooled to 30 ° C.
[0022]
Next, an unsaturated polyester resin was used as a matrix resin for FRP, and calcium carbonate was used as a filler. As the reinforcing fiber for FRP (D), glass fiber was used, and its form was a combination of roving and swirl mat.
[0023]
As the pattern material (A) for the surface layer, a non-woven fabric of polyester fiber printed in advance with a pattern was used.
[0024]
As the sheet / film material layer (B) with a plurality of holes in the thickness direction, vinylon fiber yarns are arranged in three directions (60 degrees), equilateral triangles are formed into lattices, and an alkali-resistant binder is used. A braided cloth was used.
[0025]
A glass fiber chopped strand mat was used as the mat or woven fiber reinforcement (C).
[0026]
After the FRP reinforcement (D) is passed through the matrix resin impregnation tank and impregnated with the matrix resin, on the forming guide (b), there are a plurality of holes in the direction of thickness (A) and (B) from the top. Die (a) while opening sheet / film material, glass fiber chopped strand mat, (D) reinforcing material for FRP impregnated with matrix resin in order and preforming into die cross-sectional shape by forming guide (b) In order to improve the luster and texture by forming a clear resin layer on the surface layer as well as pulling it into the hole, a resin compound with a matrix of unsaturated polyester resin is press-fitted into the matrix injection space (x) provided on the die a. However, it was molded at a drawing speed of 50 cm / min to obtain a panel-shaped molded body having a cross-sectional shape shown in FIG.
[0027]
The obtained molded body had a panel shape with a wall thickness of 4 mm, a width of 370 mm, and both flange heights of 40 mm. This panel surface layer was provided with a regular triangular pattern, and the appearance design was excellent.
[0028]
【The invention's effect】
According to the present invention, an FRP molded product having a concavo-convex pattern on the surface can be efficiently obtained by a pultrusion molding method, and a concavo-convex pattern is easily provided even on a standing surface portion that has conventionally been difficult to form integrally. Things are possible. Further, it is possible to easily obtain an FRP molded product provided with a concavo-convex pattern perpendicular to the drawing direction of the molded product, which was difficult with the conventional pultrusion molding method.
[0029]
[Brief description of the drawings]
FIG. 1 is a diagram showing the configuration of a die (a), a forming guide (b), a matrix resin impregnation tank (c), and materials installed in a pultrusion molding machine in Example 1. FIG.
FIG. 2 is a detailed sectional view of a die (a) used in Example 1. FIG.
FIG. 3 is a cross-sectional view in which the axial direction of the panel-shaped molded product obtained by pultrusion in Example 1 is the normal direction.
4 is a sheet / film material (vinylon fiber yarn assembly) having a plurality of holes in the thickness direction used in Example 1. FIG.
[Explanation of symbols]
(A): Die (b): Forming guide (c): Matrix resin impregnation tank (x): Space for matrix resin injection (y): Cooling circuit (1): Pattern material (printed polyester fiber nonwoven fabric)
(2): Sheet / film material with multiple holes in the thickness direction (Vinylon fiber yarn assembly)
(3): Matt or woven fiber reinforcement (glass fiber chopped strand mat)
(4): FRP fiber reinforcement (glass fiber roving)
(5): FRP fiber reinforcement (glass fiber swirl mat)
(6): Hole in the thickness direction (void)
(7): Yarn
(A): Surface layer made of pattern material
(B): Sheet / film material layer with multiple holes in the thickness direction
(C): Matt or woven fiber reinforcement layer
(D): FRP molding material layer

Claims (4)

From the surface, (A) a surface layer made of a pattern material pre-printed with a pattern on a non-woven fabric, woven fabric or paper , (B) a sheet / film material layer with a plurality of holes in the thickness direction, (C) a mat or woven fabric An FRP molded product comprising a fiber reinforcing material layer, (D) an FRP molding material layer, and having a concavo-convex pattern on the surface.   2. The FRP molded product according to claim 1, which is produced by a pultrusion molding method.   (A) Surface layer made of pattern material, (B) Sheet / film material layer with multiple holes in the thickness direction, (C) Mat or woven fiber reinforcing material layer, (D) FRP molding material A method for producing an FRP molded product having a concavo-convex pattern, characterized by heat-molding a molding material having a cross-sectional structure composed of layers.   The FRP molded article according to claim 1, wherein the opening ratio of the sheet / film material (B) is 30 to 99.9%.

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