JPH05147145A - Composite molded article and production thereof - Google Patents

Abstract

PURPOSE:To provide a composite molded article generating no surface peeling or rupture even during long-time use, capable of always keeping good appearance and having a logotype mark, a brand name, a design pattern or various color rings applied to the outer surface thereof. CONSTITUTION:Each of shell parts 2A, 2B of an attache case consists of two or more fiber reinforced resin layers 4, 6, 8 and the first fiber reinforced resin layer 4 forming the outermost layer of each of the shell parts 2A, 2B is composed of a resin rich fiber reinforced prepreg layer whose matrix resin is at least 50-65wt.%. Further, a surface prepreg layer 10 is provided to the outer surface of the first resin rich fiber reinforced prepreg layer 4. The surface prepreg forming the surface prepreg layer 10 is formed by applying a resin to one surface of a surface film 10a having a logotype mark, a brand name, a design pattern or the like printed thereon.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a bag made of a plurality of fiber reinforced resin layers, such as an attache case,
The present invention relates to a composite material molded product such as a golf club shaft, a pipe material such as a fishing rod or a bicycle frame, a plate material such as a decorative wall board, and particularly, a logo mark, a brand name, a design pattern on the outer surface, Alternatively, the present invention relates to a composite material molded product that has been subjected to various coloring.

[0002]

2. Description of the Related Art In recent years, for the reason of being lightweight and having high mechanical strength, various composite material moldings made of, for example, carbon fiber reinforced composite resin materials using carbon fibers as reinforcing fibers have been proposed, and Widely marketed.

Regarding an attache case as an example of such a molded composite material, the shell (body) of the attache case is made of a fiber reinforced composite resin material having reinforcing fibers such as carbon fibers. That is, the attache case is arranged in one direction, or arranged at a predetermined angle, or a fiber-reinforced prepreg obtained by impregnating carbon fibers formed in a cloth (woven fabric) with a matrix resin is laminated on a molding die. And then cured.

As described above, the attache case is lightweight and has a large mechanical strength.

[0005]

However, the attach case made of such a fiber-reinforced composite resin material is made black, especially when the reinforcing fiber is carbon fiber, and on the other hand, the glass fiber is used as the reinforcing fiber. Since it becomes white when it is used, it is desired to perform an outer surface mounting treatment such as coloring. In some cases, it is also required to provide a logo mark, brand name, design pattern, etc. on a part of the surface.

For this reason, conventionally, after the attach case shell is molded and cured, the outer surface of the shell is painted in a predetermined color or pattern, or the outer surface of the shell is
It was inevitable to attach a mounting film having a predetermined color or pattern, and further, a logo mark, a brand name, etc. printed thereon.

The attache case produced by this method has not only a high-grade appearance, but also the outer surface of the attache case may come into contact with other objects or be rubbed by long-term use, and the surface coating may be peeled off or the covering film may be removed. There was a problem that it was torn or it was unsightly in appearance.

Therefore, the object of the present invention is to prevent the surface from peeling or breaking even after many years of use, and to always maintain a good appearance. It is an object of the present invention to provide a high quality composite material molded product having a design pattern or various colorings and a method for producing the same.

[0009]

The above object can be achieved by the molded composite material and the method for producing the same according to the present invention. In summary, the present invention relates to a composite molded article composed of a plurality of fiber-reinforced resin layers, wherein the outermost fiber-reinforced resin layer is a resin-rich fiber-reinforced prepreg layer containing at least 50 to 65% by weight of a matrix resin. Further, the whole or a part of the outer surface of the resin-rich fiber-reinforced prepreg layer is provided with a cover prepreg layer in which at least the outer surface of a cover film is coated with a resin, and the inner surface of the cover prepreg layer is the resin-rich fiber reinforced layer. The composite material molded article is characterized in that it is integrally provided so as to be located on the prepreg layer side. The surface layer prepreg layer is formed by directly coating a resin on at least the outer surface of the surface mounting film, or on both surfaces of the surface mounting film with or without a resin having a thickness of 20 to 100 μm. A thin glass fiber reinforced prepreg layer is laminated, and at least the outer surface thereof is coated with a resin.

The above-mentioned composite material molded article can be produced by various methods, but in particular, (a) matrix resin is at least 5
An outer surface of a resin-rich fiber-reinforced prepreg in an amount of 0 to 65% by weight is entirely or partially covered with a resin-coated fiber at least on the outer surface of a resin-coated fiber prepreg. The step of sticking so as to be positioned on the prepreg side, (b) the mold surface of the molding die is subjected to a mold release treatment, and the fiber reinforced prepreg having the surface prepreg formed in step (a) is stuck to the surface prepreg. Laminating on the molding surface of the mold so that the attached side becomes the molding surface, (c) laminating another fiber-reinforced prepreg on the inner surface of the resin-rich fiber-reinforced prepreg, if necessary. And (d) a pressure-reducing treatment is performed to sufficiently defoam voids between the molding surface of the molding die and the prepreg and between the prepregs. It can be preferably produced by a manufacturing method characterized by comprising the steps of curing heat.

According to another embodiment, in the above-mentioned composite material molded article, (a) at least the outer surface of the mounting film is coated with a resin on the whole or a predetermined position of the molding surface of the mold subjected to the mold release treatment. A step of adhering the above-mentioned cover prepreg, (b) a step of laminating a resin-rich fiber-reinforced prepreg in which the matrix resin is at least 50 to 65% by weight on the molding surface of the above-mentioned molding die, covering the cover prepreg. ) A step of laminating another fiber-reinforced prepreg on the inner surface of the resin-rich fiber-reinforced prepreg, if necessary, and (d) a void between the molding surface of the mold and the prepreg and in each prepreg. And a step of heating and curing each of the prepregs in order to sufficiently remove air bubbles.

Further, according to another preferred embodiment, in the above-mentioned composite material molded article, (a) the mandrel is subjected to a mold release treatment,
A step of winding a fiber-reinforced prepreg, (b) a step of winding a resin-rich fiber-reinforced prepreg having a matrix resin of at least 50 to 65% by weight on the outside of the fiber-reinforced prepreg, and (c) a resin-rich fiber-reinforced prepreg The whole or a part of the outer surface of, a step of attaching a cover prepreg in which at least the outer surface of the cover film is coated with a resin so that the inner surface of the cover prepreg is located on the resin-rich fiber-reinforced prepreg side,
(D) A step of winding a heat-resistant tape around the outside of the prepreg wound around the mandrel so as to sufficiently remove air bubbles between the mandrel and the fiber-reinforced prepreg and between the prepregs, and (e) each prepreg. It can be preferably manufactured by a manufacturing method characterized by comprising a step of heating and curing.

[0013]

EXAMPLES Next, the molded composite material and the method for producing the same according to the present invention will be described in more detail with reference to the drawings.

In the first embodiment of the present invention, the composite molded article of the present invention is described as the shell portion of the attache case.

According to the present embodiment, the shell portion 2 (2A, 2B) of the attache case 1 is, as shown in FIG.
Each is a thin rectangular box having a substantially rectangular shape and having substantially the same shape. The shell portion 2 (2A, 2B) is formed of a plurality of fiber reinforced resin layers formed by laminating a plurality of layers of fiber reinforced prepreg having reinforcing fibers such as carbon fibers and curing the layers.

That is, referring to FIG. 1, the shell portion 2 is composed of the first, second and third fiber reinforced resin layers 4, 6 and 8 from the outside. Each fiber reinforced resin layer 4,
The reinforcing fibers 6 and 8 are arranged in one direction, arranged at a predetermined angle, or formed in a cloth (woven fabric). As the reinforcing fiber, carbon fiber,
Glass fibers, organic fibers, metal fibers, and various other fibers may be used alone or in combination of two or more. For example, the first
The fiber-reinforced resin layer 4 is a carbon fiber cloth prepreg layer in which carbon fiber alone or a cloth (woven fabric) in which carbon fiber and aramid fiber are woven is used as the reinforcing fiber, and the second fiber-reinforced resin layer 6 is made of glass fiber. Can be used as a glass fiber prepreg layer, and the third fiber-reinforced resin layer 8 can be a carbon fiber cloth prepreg layer having carbon fiber cloth as a reinforcing fiber.

If necessary, for example, between the first fiber-reinforced resin layer 4 and the second fiber-reinforced resin layer 6, or between the second fiber-reinforced resin layer 6 and the third fiber-reinforced resin layer. It is also possible to interpose a core material (not shown) made of a vinyl chloride foam material, cork, or the like between the two. By providing these core materials between the fiber-reinforced resin layers, the strength and rigidity of the shell portion can be increased, the collision noise when an object hits the shell portion is reduced, and the attache case 1 is given a solid feeling. be able to.

According to the present invention, the first fiber-reinforced resin layer 4, which is the outermost layer of the shell portion 2, is a resin rich material in which the matrix resin is at least 50 to 65% by weight, preferably 55 to 60% by weight. It is used as a fiber reinforced prepreg layer. In the first fiber-reinforced resin layer 4, the matrix resin content is 50
If it does not reach the weight percentage, as will be described later in detail, voids are frequently formed on the outer surface of the shell portion, which causes a problem that the appearance becomes unsightly. Further, when the content of the matrix resin exceeds 65% by weight, problems such as defective molding occur.
On the other hand, the second and third fiber-reinforced resin layers 6 and 8 have a normal matrix resin content of 40% by weight or less of the matrix resin in order to maintain the rigidity and strength of the shell portion 2. Reinforced prepreg layer.

The matrix resin used in the prepreg for forming each of the fiber reinforced resin layers 4, 6, 8 may be, but is not limited to, the same matrix resin such as epoxy resin, unsaturated polyester resin, Thermosetting matrix resins such as polyurethane resin, diallyl phthalate resin and phenol resin can be used. Further, to the matrix resin, a curing agent and other imparting agents such as flexibility imparting agent are appropriately added so that the curing temperature is 50 to 200 ° C.

As a preferred example, an epoxy resin is preferable as the matrix resin, and usable epoxy resins include, for example, (1) glycidyl ether type epoxy resins (bisphenol A, F, S type epoxy resin, novolac type epoxy resin). Resin, brominated bisphenol A epoxy resin); (2) cycloaliphatic epoxy resin;
(3) Glycidyl ester-based epoxy resin; (4) Glycidylamine-based epoxy resin, tetraglycidyldiaminodiphenylmethane, triglycidyl-p-aminophenol, etc .; (5) Heterocyclic epoxy resin; and other various epoxy resins. One kind or a plurality of kinds are used, and bisphenol A, F, S glycidyl amine epoxy resin is particularly preferably used. As the curing agent, an amine-based curing agent such as dicyandiamide (DIC
Y), diaminodiphenylsulfone (DDS), diaminodiphenylmethane (DDM); acid anhydrides such as hexahydrophthalic anhydride (HHPA) and methylhexahydrophthalic anhydride (MHHPA) are used, but especially amine curing Agents are preferably used.

Further in accordance with the present invention, as better understood with reference to FIG. 2 as well, an exterior prepreg layer 10 is provided on the outer surface of the resin rich first fiber reinforced prepreg layer 4. As shown in FIG. 3, the covering prepreg 10 ′ forming the covering prepreg layer 10 is a covering film 1 on which a logo mark, a brand name, a design pattern and the like are printed.
Resin 10b is coated on one side of 0a. or,
As shown in FIG. 4, resin 1 is provided on both sides of the covering film 10a.
It is also possible to coat 0b.

According to the present invention, as shown in FIG. 1, the covering film 10a is not exposed on the outer surface of the shell portion 2 and is embedded inside the shell portion 2 so as to be integrated with the shell portion. To be done. Therefore, even if the attache case 1 hits or rubs against another object due to long-term use, the surface of the outer covering film 10a is covered with a resin and is protected, so that the outer covering film 10a is broken, It does not peel off, and it solves problems such as unsightly appearance.

In the above description, the covering prepreg layer 10 is provided on a part of the shell portion 2. However, for example, when coloring or designing the entire outer surface of the shell portion 2, the covering prepreg layer 10 is formed. The layer 10 can be provided over the first fiber reinforced prepreg layer 4.

Surface mounting film 10 of surface mounting prepreg 10 '
It is preferable that a is capable of printing a desired logo mark or the like, and that the resin 10b coated on the surface thereof can be melted and penetrated at least when the surface mounted prepreg 10 'is heated. Paper, cloth, resin-permeable plastic film, etc. For example, as the resin-penetrable plastic film, rayon or other recycled fiber or semi-synthetic fiber, or nylon,
There are dyed, woven and knitted fabrics and non-woven fabrics made of polyester, acrylic and other synthetic fibers. It is preferable that such a fiber cloth has a decorative effect by an ordinary woven pattern, print, dyeing, etc., but it is not particularly limited thereto.

The resin 10b of the surface mounted prepreg 10 'is preferably the same as the matrix resin used in the prepreg 4'for the first fiber reinforced prepreg layer 4, for example, the epoxy resin. Resin 1 in general
The coating thickness of 0b is 20 to 80 μm.

In FIGS. 5 and 6, the surface mounted prepreg 10 'is shown.
Another embodiment of is shown.

According to the embodiment of FIG. 5, the surface mounted prepreg 1
0'is sandwiched between both sides of the surface mounting film 10a by an extremely thin glass fiber reinforced prepreg 10c having a thickness of preferably 20 to 100 μm, and at least one side thereof, that is, the outer surface is covered with the resin 10b. To be done.

Further, as shown in FIG. 6, the ultra-thin glass fiber reinforced prepreg 10c is laminated on both sides of the covering film 10a with the resin 10b ₁ interposed therebetween, and the resin 10b is provided at least on one side thereof, that is, on the outer side. It is also possible to adopt a configuration in which ₂ is covered.

In the glass fiber reinforced prepreg 10c, as the reinforcing fibers, glass fibers arranged in one direction or at a predetermined angle, or glass fibers formed into a cloth (woven fabric) can be used. As the matrix resin, any matrix resin can be used, and thermosetting matrix resins such as epoxy resin, unsaturated polyester resin, polyurethane resin, diallyl phthalate resin, and phenol resin can be used. The same matrix resin as that used in the prepreg 4'for the first fiber-reinforced prepreg layer 4 is preferable, for example, an epoxy resin is preferable. Matrix resin content is usually 30
-60% by weight. Further, to the matrix resin, a curing agent and other imparting agents such as flexibility imparting agent are appropriately added so that the curing temperature is 50 to 200 ° C.

Further, in the embodiment shown in FIGS. 5 and 6,
The resins 10b, 10b ₁ and 10b ₂ can be the same resin and, as mentioned above, the matrix resin used for the prepreg 4 ′ for the glass fiber reinforced prepreg 10c and the first fiber reinforced prepreg layer 4. The same thing is preferable, for example, the above-mentioned epoxy resin is used. Generally, the coating thickness of these resins 10b, 10b ₁ and 10b ₂ is 20
˜80 μm.

In the cover prepreg 10 'according to the embodiments of FIGS. 5 and 6, since the cover film 10a is sandwiched by the glass fiber reinforced prepregs 10c, the cover prepreg 10' is cut (punched) into a desired shape. In doing so, there is little deviation on the punching die, and there is an advantage that punching can be performed more accurately as compared with the case-equipped prepreg 10 ′ of the embodiment shown in FIGS. 3 and 4. Furthermore,
The cured product has the advantage that the durability of the covering film 10a is significantly improved because the covering prepreg layer 10 is sandwiched between the extremely thin glass fiber reinforced prepreg (10c) layers.

The composite molded article according to the present invention having the above-mentioned constitution is
Although it can be manufactured by various methods according to the desired composite molded product, a method of manufacturing the attache case shell portion 2 according to the above-described embodiment will be described below.

First, as shown in FIG. 3, a covering prepreg 10 'is provided on the outer surface of a resin-rich fiber reinforced prepreg 4'wherein the matrix resin produced by the usual method is at least 50 to 65% by weight. It can be pasted. The covering prepreg 10 ′ is arranged so that the coating resin 10 b side is located outside on the whole or a desired part of the outer surface of the fiber reinforced prepreg 4 ′, that is, in the present embodiment, the covering film 10 ′.
It is attached so that a is located on the resin-rich fiber reinforced prepreg 4 ′ side.

On the other hand, the molding surface 100a of the molding die 100 is subjected to a mold release treatment, and the fiber reinforced prepreg 4'on which the above-mentioned cover prepreg 10 'is attached is attached to the cover prepreg 1.
It is laminated on the molding die 100 so that the side to which 0'is attached is positioned on the molding surface 100a.

Next, as shown in FIG. 3, prepregs 6 ', 8'for forming second and third fiber-reinforced prepreg layers 6, 8 on the resin-rich fiber-reinforced prepreg 4'. Stack. Usually, voids (air) are present between the molding surface 100a of the molding die 100 and the fiber reinforced prepreg 4'to which the surface prepreg 10 'is attached, and in each of the prepregs 4', 6 ', 8'. Therefore, the air is depressurized so that the air is sufficiently defoamed.
The reduced pressure treatment can be performed according to a usual method.
That is, the vacuum bag 102 is placed on the molding die 100 so as to cover the laminated prepregs 4 ′, 6 ′ and 8 ′, and after the bagging process, the inside is evacuated and at the same time, the prepregs 4 ′, 6 ′ and 8 ′ are simultaneously evacuated. 'Is between the molding surface 100a and the fiber reinforced prepreg 4'to which the surface mounting prepreg is attached, before the matrix resin of the prepreg is gel-cured.
And, each prepreg 4 ', 6', 8'is heated to a desired temperature in an autoclave so that defoaming is sufficiently performed. At this time, the degree of decompression and the increase in temperature are controlled so as to achieve complete defoaming from each prepreg, particularly from the fiber-reinforced prepreg 4 ′. by this,
Each of the prepregs 4 ', 6', 8 ', 10' is cured to form a composite molded product.

At this time, if the content of the matrix resin in the first resin-rich fiber-reinforced prepreg 4'has not reached 50% by weight, the fiber-reinforced prepreg 4'with the cover prepreg 10 'attached thereto. Between the mold 100 and the mold 100, and the voids (air) present in the resin-rich fiber-reinforced prepreg 4'cannot be sufficiently defoamed, and as a result, voids are frequently formed on the outer surface of the shell portion 2, It looks hard on the outside.

According to the manufacturing method of the above-mentioned embodiment, the surface mounted prepreg 10 'is provided on the outer surface of the resin-rich fiber reinforced prepreg 4'.
After the attachment, the fiber reinforced prepreg 4 ′ to which the outer prepreg 10 ′ is attached is attached to the outer prepreg 1
Although it has been described that the molding die 100 is laminated so that the side to which 0'is attached is positioned on the molding surface 100a, in another embodiment, the molding surface 100a of the molding die 100 subjected to the mold release treatment is directly attached to the molding surface 100a. The exterior prepreg 10 ′ may be attached, and the resin-rich fiber reinforced prepreg 4 ′ and the other prepregs 6 ′ and 8 ′ may be laminated in this order.

Next, as still another embodiment of the present invention, a case where the composite material molded product of the present invention is a golf club shaft will be described.

According to this embodiment, the golf club shaft 31 is composed of a plurality of fiber reinforced resin layers formed by laminating a plurality of fiber reinforced prepregs having reinforcing fibers such as carbon fibers and curing them. It is formed.

That is, referring to FIG. 7, the golf club shaft 31 is composed of the first, second and third fiber reinforced resin layers 34, 36 and 38 from the inside.
The reinforcing fibers of the fiber-reinforced resin layers 34, 36 and 38 are arranged in one direction, arranged at a predetermined angle, or formed in a cloth (woven fabric). As the reinforcing fiber, carbon fiber, glass fiber, organic fiber, metal fiber, and other various fibers may be used alone or in combination of plural kinds. For example, the first fiber-reinforced resin layer 34 is a glass fiber cloth prepreg layer, and the second fiber-reinforced resin layer 36 is a carbon fiber in which carbon fibers are arranged at an angle of 35 ° in opposite directions to the fiber axis. As the prepreg layer, the third fiber-reinforced resin layer 38 may be a carbon fiber prepreg layer in which carbon fibers are arranged in the fiber axis direction (0 °) and orthogonal to the axis direction (90 °).

According to the present invention, at least the outermost prepreg layer of the third fiber reinforced resin layer 38 forming the outer layer of the shaft 31 contains at least 50 to 50% of matrix resin.
The resin-rich fiber-reinforced prepreg layer is set to 65% by weight, preferably 55 to 60% by weight.

As the matrix resin used in the prepreg for forming each of the fiber reinforced resin layers 34, 36, 38, the same one as described in the previous embodiment can be used.

Further, according to the present invention, the above-mentioned cover prepreg layer 10 is provided on the outer surface of the resin-rich fiber reinforced prepreg layer of the third fiber reinforced resin layer 38.
Outer prepreg 10 ′ forming the outer prepreg layer 10
As shown in FIG. 3, the resin 10b is coated on one side of the cover film 10a on which a logo mark, a brand name and the like are printed. Further, as shown in FIG. 4, it is possible to cover both sides of the covering film 10a with the resin 10b. Further, as shown in FIGS. 5 and 6, an ultrathin glass fiber reinforced prepreg having a thickness of 20 to 100 μm is laminated on both surfaces of the surface mounting film with or without resin, and at least the outer surface thereof. It is also possible to use a surface-mounted prepreg 10 ′ coated with a resin.

Further, the surface mounted prepreg layer 10 may be provided on a part of the golf club shaft 31, or may be provided entirely on the entire outer surface of the shaft.

A method of manufacturing the golf club shaft having the above structure will be described.

Similarly to the conventional practice, an elongated mandrel is prepared and the mandrel is subjected to a mold release treatment. Then, on the mandrel, the fiber reinforced resin layer 34,
Fiber reinforced prepreg 3 for forming 36, 38
A predetermined number of 4 ', 36', 38 'are wound. At this time, at least the fiber-reinforced prepreg 3 located in the outermost layer
8'is at least 50-65 wt% matrix resin
It is said to be a resin-rich fiber-reinforced prepreg.

Subsequently, the exterior prepreg 10 'is attached to the outer surface of the resin-rich fiber reinforced prepreg 38'. The covering prepreg 10 ′ is formed on the whole or a desired part of the outer surface of the fiber reinforced prepreg 38 ′ by the coating resin 1 ′.
It is attached so that the 0b side is located outside, that is, the covering film 10a is located on the resin-rich fiber reinforced prepreg side in this embodiment.

Next, a heat-resistant tape such as polypropylene tape is wound around the outside of the prepreg wound around the mandrel. At this time, 5k for heat resistant tape
Wrap it by applying tension of about g and tightening. As a result, the voids between the mandrel and the fiber reinforced prepreg and in the prepregs are sufficiently defoamed. After this, heat to a predetermined temperature in the oven,
Heat cure each prepreg.

In the above embodiments, the composite material molded product of the present invention is described as a shell portion of an attache case or a pipe material such as a golf club shaft, but the composite material molded product of the present invention is not limited to this. It is to be understood that other types of bags or pipe materials other than golf club shafts, such as fishing rods or bicycle frames, plate materials such as decorative wallboards, etc. may be used.

Next, the present invention will be described in more detail with reference to Examples.

Example 1 In this example, the attache case shown in FIGS. 1 and 2 was produced. A carbon fiber cloth (woven fabric) was used as a reinforcing fiber, and an epoxy resin was used as a matrix resin to prepare a resin-rich fiber-reinforced prepreg 4 ′ having a matrix resin content of 55% by weight. The thickness of this fiber reinforced prepreg 4'was 0.3 mm.

The covering prepreg 10 ′ is a covering film 10 which is a paper having a width of 3 cm × a length of 15 cm and a thickness of 50 μm.
As shown in FIG. 2, a mark “TONEN” is printed on a and the printed surface has a thickness of 10 μm and the epoxy resin 10 has a thickness of 10 μm.
It was manufactured by applying b.

Then, the covering prepreg 10 ′ is coated on the desired portion of the outer surface of the fiber reinforced prepreg 4 ′ with the coating resin 10 ′.
It was attached so that the side b was located outside.

The fiber reinforced prepreg 4 ′ thus attached with the surface prepreg 10 ′ is placed at a predetermined position on the molding surface 100 a of the mold 100 subjected to the mold release treatment.
The molding surface 100a is the side to which the exterior prepreg 10 'is attached.
It was laminated on the mold 100 so as to be positioned at.

Then, second and third fiber-reinforced prepregs 6 ', 8'were laminated on the resin-rich fiber-reinforced prepreg 4'. Second fiber reinforced prepreg 6 '
The glass fiber cloth was used as the reinforcing fiber and the epoxy resin was used as the matrix resin, and the matrix resin content was 40% by weight. The third fiber-reinforced prepreg 8'uses carbon fiber cloth as the reinforcing fiber and epoxy resin as the matrix resin,
The matrix resin content was 37% by weight. The thicknesses of the second and third fiber-reinforced prepregs 6 ′ and 8 ′ are both 0.2.
mm, and they were laminated one by one on the fiber-reinforced prepreg 4 ′.

A vacuum bag was placed on the mold, covering the laminated prepregs, and after bagging, the inside was evacuated to about 2 mmHg to sufficiently reduce the pressure.
At the same time, each prepreg was heated and cured until the final temperature reached 130 ° C.

The attache case shell portion 2 thus obtained had no voids on its outer surface, was aesthetically superior in appearance, and was satisfactory in both rigidity and strength. The covering film 10a was located slightly inward of the outer surface of the shell portion, and the mark "TONEN" was extremely clearly observed from the outside, which was extremely preferable.

Example 2 In this example, the golf club shaft shown in FIG. 7 was manufactured.

An epoxy adhesive was applied to the release-treated mandrel, and the first, second, and third fiber-reinforced prepregs 34 ', 36', and 38 'were wound. The first fiber-reinforced prepreg 34 'used glass fiber cloth as the reinforcing fiber and epoxy resin as the matrix resin, and had a matrix resin content of 40% by weight. The second fiber reinforced prepreg 36 ′ is a carbon fiber prepreg in which carbon fibers are arranged so as to be inclined at 35 ° in mutually opposite directions with respect to the fiber axis, an epoxy resin is used as the matrix resin, and the matrix resin content is 37. % By weight. The third fiber-reinforced prepreg 38 ′ is a carbon fiber prepreg in which carbon fibers are arranged in the fiber axis direction (0 °) and orthogonal (90 °) to the axis direction, and an epoxy resin is used as a matrix resin, and a matrix is used. The resin-rich prepreg had a resin content of 55% by weight.

Each fiber reinforced prepreg 34 ', 36', 3
No. 8'has a thickness of 0.2 mm, and is wound around every two rounds (two plies).

Next, the surface-mounted prepreg 10 'used in Example 1 was attached to a desired portion of the outer surface of the fiber reinforced prepreg 38' so that the coating resin 10b side was located outside.

In this manner, the prepreg to which the surface prepreg 10 'was adhered was wound so as to be tightly wound with a polypropylene tape having a tension of 5 kg, and heated in an oven until the final temperature reached 140 ° C. to cure. did.

The golf club shaft 31 thus obtained had no voids on its outer surface, was aesthetically excellent, and was satisfactory in both rigidity and strength. The covering film 10a was located slightly inward of the outer surface of the shaft, and the mark "TONEN" was extremely clearly observed from the outside, which was extremely preferable.

Example 3 In Example 3, in Example 2, between the second fiber reinforced prepreg 36 'and the third fiber reinforced prepreg 38', an aramid fiber reinforced prepreg was further provided only two times (2 plies). A golf club shaft shown in FIG. 7 was manufactured by using the same material and method as in Example 2 except that the golf club shaft was wound.

The aramid fiber reinforced prepreg was prepared by using aramid fibers arranged in the axial direction as the reinforcing fibers and using an epoxy resin as the matrix resin.
The matrix resin content is 40% by weight and the thickness is 0.1
It was 7 mm.

The golf club shaft thus obtained had no voids on its outer surface, was aesthetically excellent, and was satisfactory in both rigidity and strength. The covering film 10a was located slightly inward of the outer surface of the shaft, and the mark "TONEN" was extremely clearly observed from the outside, which was extremely preferable.

Example 4 In this Example 4, an attache case as shown in FIGS. 1 and 2 was made with the same materials and method as in Example 1 except that the prepreg shown in FIG. 5 was used as the surface mounted prepreg 10 ′. did.

That is, the cover prepreg 10 'has a width of 3c.
As shown in FIG. 2, the mark "TONE" is formed on the cover film 10a, which is a paper of m × 15 cm in length and 50 μm in thickness.
"N" is printed, and a thickness of 8 is applied to both surfaces of the covering film 10a.
An ultrathin glass fiber reinforced prepreg 10c having a thickness of 0 μm was laminated. Further, one glass fiber reinforced prepreg 10c
Epoxy resin 10b having a thickness of 70 μm was applied to the outer surface of the.

Ultra-thin glass fiber reinforced prepreg 10
c was produced by using unidirectionally arranged glass fibers as the reinforcing fibers and epoxy resin as the matrix resin, and the matrix resin content was set to 37% by weight.

The attache case shell portion 2 thus obtained had no voids on its outer surface, was aesthetically excellent, and was satisfactory in both rigidity and strength. The covering film 10a was located slightly inward of the outer surface of the shell portion, and the mark "TONEN" was extremely clearly observed from the outside, which was extremely preferable.

Example 5 In this Example 5, an attache case as shown in FIGS. 1 and 2 was made by using the same material and method as in Example 1 except that the prepreg shown in FIG. 6 was used as the surface mounted prepreg 10 ′. did.

That is, the cover prepreg 10 'has a width of 3c.
As shown in FIG. 2, the mark "TONE" is formed on the cover film 10a, which is a paper of m × 15 cm in length and 50 μm in thickness.
First, print "N" on both sides of this cover film 10a.
The epoxy resin 10b ₁ was applied to a thickness of 70 μm, and then an ultrathin glass fiber reinforced prepreg 10c having a thickness of 80 μm was laminated on both surfaces of the surface mounting film 10a. Further, the epoxy resin 10b ₂ was applied to the outer surface of one glass fiber reinforced prepreg 10c in a thickness of 70 μm.

Ultrathin glass fiber reinforced prepreg 10
c was produced by using unidirectionally arranged glass fibers as the reinforcing fibers and epoxy resin as the matrix resin, and the matrix resin content was set to 37% by weight.

The attache case shell portion 2 thus obtained had no voids on its outer surface, was aesthetically superior, and was satisfactory in both rigidity and strength. The covering film 10a was located slightly inward of the outer surface of the shell portion, and the mark "TONEN" was extremely clearly observed from the outside, which was extremely preferable. Embodiments 6 and 7 In Embodiments 6 and 7, a mounting prepreg 10 'is attached to a predetermined position of the molding surface 100a of the mold 100 that has been subjected to the mold release treatment, and then the mounting prepreg 10' is attached. Example 4 except that the resin-rich fiber-reinforced prepreg 4 ′ and the second and third fiber-reinforced prepregs 6 ′ and 8 ′ were laminated on the molding die 100 to cover the
Then, an attache case as shown in FIGS. 1 and 2 was produced by using the same material and method as in Example 5.

The attache case shell portion 2 thus obtained had no voids on its outer surface, was aesthetically excellent, and was satisfactory in both rigidity and strength. The covering film 10a was located slightly inward of the outer surface of the shell portion, and the mark "TONEN" was extremely clearly observed from the outside, which was extremely preferable. Examples 8 and 9 In Examples 8 and 9, as the surface mounted prepreg 10 ′,
Outer prepreg 10 ′ used in Example 4 and Example 5
A golf club shaft 31 as shown in FIG. 7 was manufactured by using the same material and method as in Example 2 except that the surface mounted prepreg 10 ′ used in 1) was used.

The golf club shaft 31 thus obtained had no voids on its outer surface, was aesthetically excellent, and was satisfactory in both rigidity and strength. The covering film 10a was located slightly inward of the outer surface of the shaft, and the mark "TONEN" was extremely clearly observed from the outside, which was extremely preferable.

[0077]

As described above, in the molded composite material according to the present invention, the logo mark, brand name, design pattern, or various coloring provided on the outer surface is peeled off even after many years of use. Without breaking or tearing,
It has the feature of always maintaining a good appearance. Further, according to the method for producing a composite molded article according to the present invention, the logo mark, brand name, design pattern,
Alternatively, it is possible to extremely efficiently manufacture high-quality composite material molded products with various colorings.

[Brief description of drawings]

FIG. 1 is a cross-sectional configuration diagram of an example of a composite material molded product according to the present invention.

FIG. 2 is a perspective view of an attache case that is an example of a composite material molded product according to the present invention.

FIG. 3 is a diagram illustrating a manufacturing method of an example of a composite material molded product according to the present invention.

FIG. 4 is a cross-sectional configuration diagram of another embodiment of the cover prepreg.

FIG. 5 is a cross-sectional configuration diagram of another example of the cover prepreg.

FIG. 6 is a cross-sectional configuration diagram of still another embodiment of the cover prepreg.

FIG. 7 is a cross-sectional configuration diagram of another embodiment of the molded composite material according to the present invention.

[Explanation of symbols]

1, 31 Composite molded product 2 Shell part 4, 38 Resin rich fiber reinforced prepreg layer 6, 8, 34, 38 2nd, 3rd fiber reinforced prepreg layer 10 Outer prepreg layer 10a Outer film 10b, 10b _1, 10b ₂ Resin 10c Ultra-thin glass fiber reinforced prepreg 100 Mold 102 Vacuum bag

─────────────────────────────────────────────────── ─── Continuation of the front page (51) Int.Cl. ⁵ Identification code Office reference number FI technical display location B29L 9:00 4F 22:00 4F

Claims (6)

[Claims] 1. A composite material molded article comprising a plurality of fiber-reinforced resin layers, wherein the outermost fiber-reinforced resin layer is a resin-rich fiber-reinforced prepreg layer containing at least 50 to 65% by weight of a matrix resin. An outer surface of the resin-rich fiber-reinforced prepreg layer, or a part of the outer surface of the resin-coated fiber-reinforced prepreg layer, and a resin-covered prepreg layer at least on the outer surface of the resin-rich fiber-reinforced prepreg layer. A composite material molded article characterized by being integrally provided so as to be located at. 2. The molded composite material according to claim 1, wherein the surface prepreg layer is formed by directly coating a resin on at least an outer surface of the surface mounting film. 3. The surface prepreg layer has a thickness of 20 on both sides of the surface mounting film with or without resin.
The composite material molded article according to claim 1, wherein an ultrathin glass fiber reinforced prepreg layer having a thickness of -100 μm is laminated, and at least an outer surface of the prepreg layer is coated with a resin. 4. The (a) matrix resin is at least 50.
A resin-rich fiber-reinforced prepreg whose outer surface is entirely or partially covered with a resin, at least the outer surface of which is coated with a resin, and the inner surface of the resin-rich fiber-reinforced prepreg is the resin-rich fiber-reinforced prepreg. The step of sticking so as to be positioned on the side, (b) the mold surface of the molding die is subjected to mold release treatment, and the fiber reinforced prepreg having the surface prepreg formed in step (a) is attached to the surface prepreg. Laminating on the molding surface of the molding die with the open side being the molding surface, (c) laminating another fiber-reinforced prepreg on the inner surface of the resin-rich fiber-reinforced prepreg, if necessary; (D) A decompression treatment is performed to sufficiently defoam voids between the molding surface of the molding die and the prepreg and between the prepregs,
And a step of heating and curing each of the prepregs. 5. A step of: (a) attaching a mounting prepreg in which at least an outer surface of a mounting film is coated with a resin, to the whole or a predetermined position of a molding surface of a mold subjected to a mold release treatment,
(B) a step of laminating a resin-rich fiber-reinforced prepreg containing at least 50 to 65% by weight of a matrix resin on the molding surface of the molding die, covering the surface mounting prepreg.
(C) a step of laminating another fiber-reinforced prepreg on the inner surface of the resin-rich fiber-reinforced prepreg, if necessary, and (d) a space between the molding surface of the mold and the prepreg and in each of the prepregs. The method for producing a composite material molded article, comprising the step of subjecting each of the prepregs to a heat treatment in order to sufficiently defoam the voids of 1. 6. A step of: (a) subjecting a mandrel to a mold release treatment and winding a fiber reinforced prepreg; and (b) at least 5 matrix resin on the outside of the fiber reinforced prepreg.
Winding a resin-rich fiber-reinforced prepreg in an amount of 0 to 65% by weight, and To
A step of attaching so that the inner surface of the cover prepreg is located on the resin-rich fiber-reinforced prepreg side,
(D) A step of winding a heat-resistant tape around the outside of the prepreg wound around the mandrel so as to sufficiently defoam voids between the mandrel and the fiber reinforced prepreg and between the prepregs, (e) each prepreg A method for producing a composite material molded article, comprising the step of heating and curing.