JPH0149119B2 - - Google Patents

Description

[Detailed Description of the Invention] <Technical Field> The present invention relates to a method for producing an FRP laminate, in which the entire outer surface of a core material made of a synthetic resin foam is covered with an exterior made of a molded body of glass fiber reinforced resin, that is, an FRP resin. This article concerns a method for manufacturing FRP laminates that are integrally coated with materials.

<Prior art> The above-mentioned laminated products combining foam and FRP molded products have been used in various ways as they combine the features of FRP molded products with excellent strength and durability and the features of lightweight and inexpensive foams. It can be used for various purposes.

For example, surfboards used for surfing and windsurfing are conventionally made by injecting and foaming polyurethane foam into the inside of a synthetic resin molded product such as polyethylene, but injection foaming of polyurethane foam is technically difficult. It was extremely difficult and troublesome, and was insufficient in terms of strength. Therefore, we combined the above foam and FRP molded body.
The use of FRP laminates is being considered.

However, in the case of FRP laminate products, multiple FRP
Because the exterior materials made of molded objects are combined and integrated, the joints between the exterior materials and the contact surfaces between the exterior materials and the core material are insufficient, resulting in gaps and differences in level, so surfboards are used. There is a drawback that seawater intrudes into the interior through the joints, and the strength of the joints decreases, and the appearance is also unsightly.

<Purpose> Therefore, the purpose of this invention is to develop a method for manufacturing FRP laminate products that solves the problems of the prior art described above and can ensure and strengthen the joints of exterior materials made of FRP molded bodies at joints without any gaps. This is what I did.

<Structure> And, as a method for achieving the above object, there is a method for manufacturing a laminate product in which the entire outer surface of a core material made of a synthetic resin foam is integrally covered with an exterior material made of a plurality of FRP molded bodies. After installing a lining material made of uncured FRP resin on the outer surface of the core material at a location corresponding to the joint between the exterior materials,
It is characterized in that the entire outer surface of the core material is covered with a plurality of exterior bodies whose inner surfaces are coated with adhesive in advance, and the core material and the exterior body are joined and integrated by pressing from the outside surface of the exterior body with a press die. .

<Example> Next, an example of the present invention will be described below with reference to the drawings.

1 to 4, the case of manufacturing a surfboard for windsurfing as an FRP laminate product is explained sequentially according to the manufacturing process.

First, as shown in FIG. 1, a narrow lining material 2 is attached to a core material 1 made of a foamed synthetic resin such as polystyrene resin along the entire circumference of the outer peripheral side. The lining material 2 is made of an uncured FRP molded body having a certain degree of flexibility, and is formed into a thin curved plate shape along the outer surface shape of the core material 1.
The lining material 2 is arranged to cover the outer surface of the core material 1 at a location corresponding to a joint position of the exterior material, which will be described later. In addition, the adhesive used for bonding is
Epoxy resin adhesives are preferred because they have excellent adhesive strength.

Next, as shown in FIG. 2, the outer surface of the core material 1 is covered with an exterior material 3 made of a plurality of FRP molded bodies.
Cover the entire surface of core material 1. The FRP molded body serving as the exterior material 3 is a molded body of FRP resin in which glass fiber or the like is impregnated and laminated with an unsaturated polyester resin in a shape corresponding to the outer surface shape of the core material 1. And for the figure,
20% exterior material 3,3 where the whole is divided into upper and lower halves in advance
is formed, and an epoxy resin adhesive 4 is applied to the inner surface of this exterior material 3, which is placed over the core material 1 to cover the entire outer surface. In addition, the outer periphery of the exterior material 3 is provided with a horizontal collar portion 30 that projects outward. In addition, filling putty 5 is placed on the outer surface of the lining material 2 corresponding to the joint portion of the upper and lower exterior materials 3.

Next, as shown in FIG. 3, press molds 6, 6 are brought into contact with the top and bottom of the exterior material 3 and pressed from above and below,
The core material 1 and the exterior material 3 are brought into close contact with each other and joined together. At this time, the flanges 30, 30 come into contact with each other at the joint portion of the upper and lower exterior members 3 and are in close contact with each other. Further, the filler putty 5 fills the gaps created between the core material 1, the lining material 2, and the exterior material 3.

After the epoxy resin adhesive 4 that joins the exterior material 3 and the core material 1 has completely cured, the flange 30 protruding from the outer periphery of the joint of the exterior material 3 is cut off and the surface is polished smoothly. For example, surfboards as shown in FIGS. 4 and 5 can be manufactured. Note that it is also possible to further finish the outer surface of the exterior material 3, such as painting or coating with synthetic resin.

Furthermore, in the case of manufacturing the above-mentioned surfboards, it is necessary to form detailed structures such as through holes and recesses for attaching parts such as daggerboards and skegs. Therefore, in order to form a daggerboard case, for example, as shown in FIG.
is formed in advance, and the above-mentioned through hole 1 is also formed in the exterior materials 3, 3.
Penetration cylinder portions 31, 31 that fit into the cylindrical portion 0 are formed in advance. During assembly, the upper and lower through-tube portions 31,
31 is inserted into the through hole 10 of the core material 1, and the two through cylinder parts 31, 31 are partially overlapped and fitted together. Note that the gap created between the inner surface of the through-cylindrical portion 31 and the core material 1 is filled with filling putty 5, which is a mixture of epoxy resin and talc. Further, FIG. 7 shows an example of forming a skeg case, in which recesses 11 and 32 for the skeg case are formed in the core material 1 and the exterior material 3, and the recesses 11 and 32 for the skeg case are formed in advance in the upper part of the recess 32 of the exterior material 3. A skeg box 7 made of FRP molded product or hard synthetic resin is inserted and bonded. In addition, in the case of the figure, Skegbox 7 and
Filling putty 5 is filled between the concave portions 32 of the FRP molded body 3 to fill the gap and at the same time adhere.

Furthermore, in order to increase the strength and rigidity of the surfboard, reinforcing girders 33 made of FRP molded products etc. are joined along the longitudinal direction to the inner surface of the exterior material 3, as shown in Fig. 8. In some cases. Incidentally, in the core material 1, a groove 12 for inserting the girder material is formed at a location corresponding to the girder material 33.

In this way, appropriate small parts, structures, etc. can be freely added depending on the purpose and shape of the FRP laminate to be manufactured. In particular, the Skegbox 7
When accuracy of shape and strength are required, as in the case shown in FIG.

Among the manufacturing methods of FRP laminate products described above,
As the foam material for the core material 1, in addition to polystyrene, foams made of polyethylene, polypropylene, styrene-ethylene copolymers, and other various synthetic resins alone, copolymers, or mixed resins can be freely used. can.

Next, the exterior material 3 is made of FRP resin made by laminating glass fiber mat or cloth impregnated with unsaturated polyester resin and molded into a certain shape. For example, in the case of a surfboard, it is about 1 mm thick. Implemented. Then, the exterior material 3 is made by laminating FRP resin on the mold, using a mold formed in advance in a shape that follows the outer surface shape of the core material 1 as a model.
Manufactured by molding and curing.

In addition, the lining material 2 is made of an FRP molded product made of FRP resin in which glass fiber or the like is impregnated and laminated with unsaturated polyester resin, similar to the above-mentioned exterior material 3, but the unsaturated polyester resin is completely It is adhered to the core material 1 in an uncured state before being cured. In addition, since the lining material 2 is completely buried inside the surfboard after completion, it can be used even if it is thinner than the outer lining material 3.

If the exterior material 3 is in the shape of a flat thick plate like the surfboard shown in the figure, it is best to divide the exterior material 3 into upper and lower halves with a seam at the outer circumferential edge for manufacturing of the exterior material 3 itself and connection with the core material 1. Although it is convenient for joining, depending on the shape and structure of the FRP laminate to be manufactured, it may be necessary to divide it into left and right or front and back parts, or if more than 30% of the exterior material
It is also possible to implement the system by combining the following. Since the position and shape of the seam will vary depending on the division shape of the exterior material 3, the lining material 2 to the core material 1 will
It is necessary to change the bonding position and shape of the press die 6, and the structure of the press die 6 must also be changed accordingly.

In addition, the exterior material 3 and the core material 1 or the lining material 2 are
It is not necessary to form it into a shape that fits completely,
Even if a gap occurs to the extent that it can be corrected by deformation of the exterior material 3, there is no problem in practical use.

In addition, in the shape of the exterior material 3, the flange portion 30 has a shape that is
Even if a positional shift or step difference occurs at the joint of the exterior material 3, it is convenient because it can be corrected by scraping the flange 30 to make it smooth, but it can also be carried out even if the flange 30 is not formed at all. .

Next, as the adhesive for bonding the exterior material 3 and the core material 1, epoxy adhesive is the most suitable as it has excellent adhesive strength and durability during use.
Other synthetic resin adhesives can also be used, such as phenolic resins, unsaturated polyesters,
Thermosetting resin-based adhesives such as chloroprene rubber, natural rubber, and other rubber-based adhesives can also be used.

In addition, as the filling putty 5, a mixture of epoxy resin and talc can reliably fill the gap between the core material 1 and the exterior material 3, and has excellent strength after hardening. It is suitable because it can also act as an adhesive. however,
Other known synthetic resin-based or synthetic rubber-based putty materials can also be used.

In addition to the surfboards shown in the figure, the FRP laminate products explained above include various sports equipment, vehicle parts such as automobiles, architectural structural members, etc.
It can be suitably applied to various articles that require lightness and low cost as well as strength and durability, and also require surface smoothness, water resistance, etc.

<Effects> According to the method of the present invention configured as described above, the exterior material 3 consisting of a plurality of pre-formed FRP molded bodies is combined to cover the entire outer surface of the core material 1 and are integrally joined. At this time, since the lining material 2 is attached in advance to the joint of the exterior materials 3 in the core material 1, the lining material 2 comes into contact with the joint between the exterior materials 3, and the seam is removed. can enhance the unity of In particular, since the lining material 2 is made of uncured FRP resin, it can be flexibly deformed to follow the shapes of the core material 1 and the exterior material 3, and it is embedded closely between the two, so there is no gap or seam. There is no need to worry about a decrease in strength.

Therefore, the manufactured FRP laminate has strong joint strength at the joints, and can be used in applications where strong impact force or vibration is applied, without worrying about the joints peeling off or disintegrating. Furthermore, since the watertightness at the joints is good, it can be suitably used in applications where it is used underwater or exposed to rainwater, etc., without any problems.

Because of the excellent integrity of the joints, the exterior material 3 that covers the entire outer surface of the core material 1 can be freely divided and formed, making it possible to form FRP laminates with complex shapes. However, by appropriately dividing and forming the exterior material 3, it can be easily manufactured, and the exterior material 3 itself can be easily molded.

As described above, the core material 1 made of foam is
The FRP laminate product is integrally coated with the exterior material 3 made of FRP molded body, without reducing the strength of the joints.
It is now possible to manufacture the core material 1 and the exterior material 3 with good integrity, and it has excellent strength and lightness.
The features of FRP laminate products can be demonstrated even more effectively, and it can greatly contribute to the expansion of applications and demand for FRP laminate products.

[Brief explanation of drawings]

The figure shows an embodiment of the invention.
Fig. 4 is a cross-sectional view showing the manufacturing process in sequence, Fig. 5 is a partially enlarged view of Fig. 4, Fig. 6 is a partially enlarged sectional view of the daggerboard case part, and Fig. 7 is a part of the skegbox part. FIG. 8 is an enlarged sectional view of a modified example. 1...Core material, 2...Inner lining material, 3...Exterior material, 4
...Adhesive, 5...Filling putty, 6...Press mold.

Claims (1)

[Claims] 1. A method for manufacturing a laminate product in which the entire outer surface of a core material made of synthetic resin foam is integrally covered with an outer material made of multiple FRP molded bodies, in which the joints between the outer material parts of the outer surface of the core material are After installing lining material made of uncured FRP resin in the corresponding locations,
The core material and the exterior body are bonded and integrated by covering the entire outer surface of the core material with a plurality of exterior bodies whose inner surfaces are coated with adhesive in advance, and by pressing from the outside surface of the exterior body with a press die. Manufacturing method for FRP laminate products.