JPH03112649A - Manufacture of composite molding - Google Patents

Abstract

PURPOSE:To manufacture a good quality composite molding by disposing a resin liquid impermeable thermoplastic resin film between a skin material and an optical curing prepreg sheet. CONSTITUTION:A light penetrable thermoplastic resin film 11 is adhered to the surface of a prepreg sheet 12. A skin material B is constituted of a sheet in which an air permeable flexible foam sheet 15 is laminated and adhered to the inside of a woven fabric 16. An optical curing prepreg sheet A and the skin material B are superimposed each other in disposing a resin liquid impermeable thermoplastic resin film 13 therebetween and the both surfaces of the laminated body 10 are heated and softened by means of a heater 30. In this instance, the surface of the skin material B is faced downward and grasped by means of clamps 20. The heater 30 is retreated therefrom and the laminated body 10 is pressed by a vacuum molding mold 40 and then the air within the mold is sucked and further the superimposed body 11 is brought into close contact with the vacuum molding mold 40 for molding. A bank of lamps 50 are moved in order to be set in keeping an appropriate distance and the resin is cured by irradiation with light. When demolded after the curing, a composite molding can be obtained which has a beautiful skin.

Description

DETAILED DESCRIPTION OF THE INVENTION (Field of Industrial Application) The present invention relates to a method for manufacturing a composite molded article having a skin material.

(Prior art) As a manufacturing technology for a composite molded body having a skin material, for example, JP-A-62-73939 discloses a skin material made by bonding a breathable soft foam sheet to cloth, and a glass fiber material. A photocurable prepreg sheet impregnated with a photocurable unsaturated polyester resin liquid is brought into close contact with the foamed sheet facing the photocurable prepreg sheet, and after heating this adhered material, the skin material is heated. A method for manufacturing a composite molded body is disclosed in which the composite molded body is formed into a desired shape by vacuum suction so that its surface is in contact with the surface of a mold, and the molded body is cured by irradiating it with light.

(Problem to be Solved by the Invention) However, in such a conventional method for manufacturing a composite molded article, during heating and vacuum suction, the prepreg sheet is impregnated into the fine pores of the foam sheet of the skin material. The photocurable unsaturated polyester resin liquid infiltrates.

Therefore, when the skin material and photocurable prepreg sheet are in close contact with each other and cured by irradiating light, the resin liquid that has penetrated into the foam sheet will harden because the light will not pass through the foam sheet. may be delayed, and uncured portions may remain.

There is also the problem that the resin liquid that has entered the foam sheet leaches onto the fabric surface of the skin material and hardens, impairing the appearance and feel of the surface of the skin material.

Note that the above-mentioned problems also occur when the skin material is made only of cloth or a breathable soft foam sheet.

Furthermore, in the prior art, the heating temperature must be set to a relatively high temperature, such as 110 to 140° C., in order to form the material well. However, when heating to such a high temperature, if the heating is too high, the monomer in the impregnated resin may evaporate, causing bubbles or tears in the resulting composite molded product.

The present invention is intended to solve the above-mentioned problems, and its purpose is to prevent the curing of the resin liquid from being delayed, to prevent uncured portions from remaining, and to prevent the appearance and feel of the surface of the skin material from being impaired. It is an object of the present invention to provide a method for manufacturing a composite molded body of good quality without being damaged.

(Means for Solving the Problems) A method for producing a composite molded article according to the first invention includes a skin material made of cloth or/and a breathable flexible foam sheet, and a reinforcing fiber material in which a photocurable unsaturated polyester resin liquid is applied. After overlapping the impregnated photocurable prepreg sheets and heating this,
When manufacturing a composite molded article by shaping the surface of the skin material so that it is in contact with the surface of the mold and curing it by irradiating it with light, there is a gap between the skin material and the photocurable prepreg sheet. It is characterized by interposing a thermoplastic resin film through which the resin liquid does not permeate.

Further, in the method for producing a composite molded article of the second invention, in the first invention, the thermoplastic resin film interposed between the skin material and the photocurable prepreg sheet is such that the resin liquid does not penetrate therethrough and the thermoplastic resin film is interposed between the skin material and the photocurable prepreg sheet. The thermoplastic resin film is characterized by being a thermoplastic resin film that swells and softens with liquid, and the heating temperature is 100°C or less.

The present invention will be described below with reference to the drawings.

In FIG. 1, A is a photocurable prepreg sheet, and this photocurable prepreg sheet A is made by impregnating a light-transmissive thermoplastic resin film 11 and a reinforcing fiber material with a photocurable unsaturated polyester resin liquid. Tenaru prepreg sheet 1
It is composed of 2.

As the reinforcing fiber material, a glass fiber non-woven fabric or woven fabric that is light-transmissive and strong is generally used, but other reinforcing fibers that do not inhibit light transmission and are strong can also be used. In addition, the photocurable unsaturated polyester resin liquid is generally a liquid unsaturated polyester resin mixed with a crosslinking monomer such as styrene and a photocuring agent such as 2,2-dimethoxy-2-phenylacetophenone. It is something. In addition, a thermosetting agent that can be cured by heating at a relatively low temperature may be used in combination with the above-mentioned photocuring agent.

The impregnated resin in the prepreg sheet 12 is in an uncured state, and the prepreg sheet 12 as a whole is flexible and its surface is sticky. Its thickness is generally 1-6ff
A material of about I1M is preferably used.

The light-transmissive thermoplastic resin film 11 is usually attached to the prepreg sheet 1 by utilizing the adhesiveness of the prepreg sheet 12.
It is attached to the surface of 2. This thermoplastic resin film 11 is provided to prevent the uncured resin from flowing out and the monomer from evaporating in the prepreg sheet 12, and to improve handling workability, but is not necessarily required.

As the light-transmitting thermoplastic resin film 11, transparent polyvinyl alcohol films of about 40 to 80 μm, acrylic resin films, saturated polyester resin films, and urethane resin films are generally used. A light-transmitting thermoplastic resin film that can be softened and shaped is preferred.

Further, in FIG. 1, B is a skin material, and this skin material B is provided to impart good surface decoration and surface feel to the composite molded article. This skin material B is composed of a non-woven fabric made of synthetic fibers or natural fibers, or a sheet in which a breathable soft foam sheet 15 is laminated on the inside of the woven fabric (1).

The skin material B is preferably one that is sufficiently elongated during heat shaping. The skin material B may be composed only of the above-mentioned nonwoven fabric or woven fabric 16 or only the breathable soft foam sheet 15.

In the present invention, the above photocurable prepreg sheet A
and skin material B are stacked so that skin material B faces the surface of the prepreg sheet 12, heated, and then shaped so that the surface of the skin material is in contact with the surface of the mold. The resin is cured by irradiation with light. At this time, a thermoplastic resin film 13 is interposed between the skin material B and the photocurable prepreg sheet A to prevent the resin liquid from penetrating therein.

The thermoplastic resin film 13 may simply be sandwiched between the skin material B and the photocurable prepreg sheet A, but it is necessary to adhere the thermoplastic resin film 13 to either the skin material B or the prepreg sheet 120 surface, especially the surface of the skin material B, in advance. It is easier to freely change the type and thickness of the prepreg sheet 12 by leaving it as is.
Moreover, it is preferable because of its good workability. If it is to be bonded to the skin material B, it is bonded using an adhesive 14 as shown in FIG. It can be bonded to the prepreg sheet 12 (in this case, it can be bonded using the adhesiveness of the prepreg sheet 12).

As the thermoplastic resin film 13 into which the resin liquid does not permeate, a polyethylene terephthalate resin film, a nylon resin film, a special grade saturated polyester resin film described below, etc., with a thickness of about 40 to 120 microns are used for -a.

In particular, a special grade saturated polyester resin film that does not penetrate the resin liquid and is swollen and softened by a component contained in the resin liquid, such as a crosslinking monomer such as styrene, is preferably used. This special grade saturated polyester resin film has terephthalic acid and ethylene glycol as its main components, along with other acid components such as isophthalic acid and glycol components such as cyclohexane dimetatool and tetramethylene glycol. Examples include films made of polymerized, low-crystalline saturated polyester resins.

Such films include r'UT G manufactured by Eastman Kodak Company in the United States and PBT manufactured by Polyplastics Company.
There are films made of resin such as (Di1 Lanex).

When this special grade saturated polyester resin film is overlapped and brought into contact with the prepreg sheet 12, it swells and softens with the resin liquid impregnated in the prepreg sheet 12, and can be shaped at a temperature of 100° C. or lower. When the sheet 12 is cured, this prepreg sheet 1
2 and is firmly adhered and integrated.

In addition, when using a thermoplastic resin film 13 that does not swell and soften with the resin liquid, the surface of the thermoplastic resin film 13 that contacts the prepreg sheet 12 may be coated with an adhesive if necessary to ensure strong adhesion. You may also obtain

The above-mentioned photocurable prepreg sheet) A and skin material B are a thermoplastic resin film 1 in which the above-mentioned resin liquid does not penetrate.
As shown in FIG. 2, the edge of this stacked body 10 is held by a clamp 20, and both sides of the stacked body 10 are heated and softened by a heater 30 to be easily deformed. make it possible to do so. In this case, the skin material B is held with the clamp 20 with its surface facing downward.

The heating temperature varies depending on the properties of the thermoplastic resin film 13. When using a thermoplastic resin film 13 that does not penetrate the resin liquid and does not swell and soften with the resin liquid, 110
It is heated to about -140°C. When using a thermoplastic resin film 13 that does not penetrate the resin liquid and is swollen and softened by the resin liquid, the temperature is 100°C or less, preferably 40 to 100°C.
``Heated to about C.

Next, after retracting the heater 30 laterally, a vacuum forming mold 40 having a desired shape is pressed against the heated and softened stacked body 10, and then the air in the mold is appropriately sucked to form the stacked body 1.
0 is brought into close contact with a vacuum mold 40 and shaped into a desired shape.

In this case, the surface of the skin material B of the stacked body 10 is shaped so as to be in contact with the surface of the vacuum mold 40.

After that, the lamp 50 is moved up and down if necessary, set at an appropriate distance, and the resin is cured by irradiating it with light.
The lamp 50 may be set by moving from the side to directly above the vacuum forming mold 40 in the same way as the heater 30.The light to be irradiated may be active light such as ultraviolet rays or visible light, particularly 300~ An ultraviolet lamp with a wavelength of 400 nm is used, and an irradiation time of several minutes is sufficient. After curing, the mold is removed and a composite molded product with a beautiful skin is obtained.

In this composite molded product, the thermoplastic resin film 13 is firmly adhered to and integrated with the photocurable prepreg sheet A and the skin material B, but the light-transmissive thermoplastic resin film 11 on the surface is There are cases where it is firmly adhered and integrated with the prepreg sheet 12, and cases where it is lightly adhered so that it can be peeled off. If it is in a peelable state, the light-transmissive thermoplastic resin film 11 is peeled off to obtain a final product. Note that instead of the vacuum molding mold 40, a pressure molding mold or a press molding mold can also be used.

(Function) According to the method of the present invention, the skin material is Since the photocurable prepreg sheet and the photocurable prepreg sheet are blocked, the resin liquid in the prepreg sheet does not leak onto the surface of the skin material.

In particular, when a thermoplastic resin film that does not penetrate the resin liquid and swells and softens with the resin liquid is used as the thermoplastic resin film, the thermoplastic resin film swells and softens with the resin liquid and stretches well. Shaping can be performed at relatively low temperatures below ℃.

(Example) Examples and comparative examples of the present invention are shown below.

Add 100 parts by weight of cliff earthworks unsaturated polyester resin liquid (#2064: manufactured by Showa Kobunshi Co., Ltd.) to a photocuring agent (Irgacure #651).
A photocurable unsaturated polyester resin liquid was prepared by mixing 0.5 parts by weight (manufactured by Ciba Geigy, Japan) and 1.5 parts by weight of a thickener (magnesium oxide).

This photocurable unsaturated polyester resin liquid is impregnated into a reinforcing fiber material made by stacking two glass fiber strand mats #450, and a transparent polyvinyl alcohol film 11 with a thickness of 80 μm is lightly pressed on the surface with a roll. As shown in Figure 1, the thickness is approximately 211 cm.
I11, a photocurable prepreg sheet A having a glass fiber content of 30% by weight was prepared.

In addition, as shown in FIG. 1, on the back side of the skin material B, which is made by laminating and bonding a breathable soft urethane foam sheet 15 with a thickness of 31 m to a stretchable woven fabric 16 with a raised surface, A transparent polyethylene terephthalate film (pH!?) 13 with a thickness of 100 μm was adhered using a urethane adhesive 14.

Next, photocurable prepreg sheet A and film (PE
T) The skin material B to which 13 has been adhered is superimposed so that the film (PET) 13 of the skin material B and the surface of the prepreg sheet 12 face each other, and this superimposed body 10 is formed as shown in FIG. After gripping with the clamp 20 and heating both sides to 110°C with the heater 30, the vacuum mold 40 is heated to about 760°C.
It was shaped by being brought into close contact with suction using Hg.

Thereafter, the resin was cured by irradiating it with a 400 DEG ultraviolet lamp from a distance of 10 cm for 3 minutes, and the mold was demolded to produce a housing-type composite molded product. This composite molded product had a beautiful raised skin material. In this case, the polyvinyl alcohol film 11 was peelable.

In Example 1, both the transparent polyvinyl alcohol film 11 with a thickness of 80μ and the transparent polyethylene terephthalate film (PET) 13 with a thickness of 100μ,
All pH! manufactured by Eastman Kodak Company in the United States! T.G.
The same procedure as in Example 1 was carried out, except that a transparent saturated polyester film having a thickness of 80 μm made of -6763 resin was used, and the heating temperature of the stacked body 10 was changed to 90° C. The resulting composite molded product had a beautiful raised skin.

Example 1 The same procedure as in Example 1 was carried out except that the transparent polyethylene terephthalate film (PET) 13 having a thickness of 100 μm was not provided.

In this case, even after irradiation with an ultraviolet lamp for 10 minutes, uncured resin remained on the surface material, resulting in a slightly sticky and poor texture.

(Effect of the invention) As mentioned above, according to the method for manufacturing a composite molded article of the present invention,
Since the skin material and the prepreg sheet are separated by a thermoplastic resin film that does not allow the resin liquid to penetrate, there is no possibility that the resin liquid will penetrate into the skin material or seep out onto the surface of the skin material, as in the prior art. Never. Therefore, it is possible to produce a composite molded article with a good texture without delaying the curing of the resin liquid, without leaving uncured portions, and without impairing the appearance and feel of the surface of the skin material.

In addition, if a thermoplastic resin film that does not permeate the resin liquid and swells and softens with the resin liquid is used as the above thermoplastic resin film, it becomes possible to shape the entire film at a relatively low temperature of 100°C or less. This prevents the evaporation of the 7-mer and does not generate bubbles in the resulting composite molded product. Moreover, it is possible to set a wide temperature range for shaping, making shaping easy and reliably preventing the occurrence of tearing. Ru.

As described above, the composite molded article produced by the method of the present invention has a good appearance and feel, and can be suitably used for automobile interior materials, wall materials, furniture materials, etc.

[Brief explanation of drawings]

FIG. 1 is a cross-sectional view showing an example of the skin material and photocurable prepreg sheet used in the method of the present invention, and FIG. 2 is a cross-sectional view showing an example of the method for manufacturing the composite molded article of the present invention. A: Photocurable prepreg sheet, B: Skin material,
DESCRIPTION OF SYMBOLS 10... Layered body, 11... Light-transparent plastic resin film, 12... Prepreg sheet, 13...
Thermoplastic resin film that does not allow resin liquid to penetrate, 14...
Adhesive, 15... Foam sheet, 16... Stretchable woven fabric, 20... Clamp, 30... Heater, 40... Vacuum mold, 50... Ultraviolet lamp.

Claims (1)

[Claims] 1. A skin material made of cloth or/and a breathable flexible foam sheet and a photocurable prepreg sheet made of a reinforcing fiber material impregnated with a photocurable unsaturated polyester resin liquid are superimposed. After heating this, it is shaped so that the surface of the skin material is in contact with the surface of the mold, and when it is irradiated with light and cured to produce a composite molded article, the skin material and photo-cured 1. A method for producing a composite molded article, which comprises interposing a thermoplastic resin film, which does not allow the resin liquid to penetrate, between the plastic prepreg sheet and the thermoplastic resin film. 2. The thermoplastic resin film interposed between the skin material and the photocurable prepreg sheet is a thermoplastic resin film that does not penetrate the resin liquid and swells and softens with the resin liquid, and that the heating temperature is The method for producing a composite molded body according to claim 1, wherein the temperature is 100°C or less.