JPH08112860A - Method of continuously manufacturing fiber reinforced plastics with embossed pattern - Google Patents

Abstract

PURPOSE: To enable embossed patterns to be achieved with more excellent producibility than that of a batching method, besides, with an irregular periodic time by transferring embossed patterns by a molding machine relative to the surface of a semi-hardened fiber reinforced plastics after having passed through the dies. CONSTITUTION: A fiber base material 1 is aligned in a pulling out direction at a predetermined degree and then introduced into a resin bath 3 so as to be impregnated with a resin 2. The resin-impregnated fiber base material 4 is lifted up from the resin bath 3 by a pulling out driving part 11 to be introduced to a heating dies 5 for allowing the resin in the fiber base material 4 to be a semi-hardened state, and thereafter an FRP 7 is conducted out of the heating dies 5. In the next place, the FRP in a semi-hardened state 7 after being conducted out of the heating dies 5 is transferred with embossed patterns on its surface by a molding machine 10 having embossed patterns formed thereon. Subsequently, the FRP 7 with embossed patterns transferred is led to a heating furnace 6 in order to be a hardened state by subjecting it to an after- curing process.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a continuous method for producing a fiber-reinforced plastic with an embossed pattern, and more specifically, it has an embossed pattern (irregular pattern) on the surface and has a decorative panel, an urban sewage treatment pond, factory wastewater, etc. The present invention relates to a continuous manufacturing method for a fiber-reinforced plastic with an embossed pattern (hereinafter referred to as an FRP with an embossed pattern), which is preferably used as a lid of the.

[0002]

2. Description of the Related Art FRP with embossed pattern is a decorative panel,
It is used for lids of urban wastewater treatment ponds and factory wastewater. Conventionally, such an FRP with an embossed pattern is press-molded using a press plate having an embossed pattern formed on the surface when press-molding a fiber reinforced plastic (hereinafter referred to as FRP),
How to transfer this embossed pattern to the FRP surface (hereinafter,
It is manufactured by a batch method). But,
This method has a drawback that the production efficiency is poor and the productivity is low because it is necessary to supply the press with a fiber base material (resin-impregnated fiber base material) impregnated with a material, that is, a resin, in a batch system. .

Studies have been made to improve this drawback, and as a result, a method for continuously producing FRP with an embossed pattern has been proposed as a means for improving productivity. For example, in JP-A-56-12735, a peelable sheet-like body (endless belt) having an embossed pattern formed on its surface is added to at least one inner surface of a die hole, and is simultaneously drawn out with a resin-impregnated fiber base material. , A method of transferring an embossed pattern on an endless belt and continuously manufacturing an FRP with an embossed pattern (hereinafter referred to as a die hole inner surface sheet interposing method) has been proposed. or,
JP-A-2-289334 discloses that a peelable sheet-like body having an embossed pattern formed on the front and back surfaces is interposed between layers of a fiber base material partially impregnated with a resin, continuously or intermittently, and a die shaft. While running in the direction, inject resin into the die, cure while impregnating the fiber base material, continuously pull out the FRP, then peel off the peelable sheet material, and continuously manufacture the embossed FRP. The method (hereinafter referred to as the intervening base material interlayer sheet method) is described.

[0004]

According to the conventional method for continuously manufacturing the FRP with an embossed pattern (that is, the method of interposing a sheet on the inner surface of a die hole and the method of interposing a base material interlayer sheet), the productivity can be improved. However, it has the following problems. That is, in the die hole inner surface sheet insertion method, since the resin-impregnated fiber base material is pulled out by interposing a peelable sheet-like body (endless belt) on at least one surface of the die hole inner surface, sliding between the endless belt and the die hole surface is performed. It is necessary to make it smooth, so it is necessary to devise a special facility around the die, such as providing a roller on the inner surface of the die hole. There is a problem that it is very difficult to do so.

On the other hand, in the intervening method of the base material interlayer sheet, the problems relating to the sliding are solved, but since the resin is directly injected into the die, the impregnation of the resin is likely to occur, and the peelability after the peeling is high. Since the sheet-shaped body cannot be reused, there is a problem that the cost becomes high.

Further, these methods are not suitable for forming an embossed pattern at an indefinite cycle because any of these methods transfers the embossed pattern with a pre-formed releasable sheet-like body, and such an FRP with such an embossed pattern is used. There is also a problem in that it cannot be manufactured. Here, forming the embossed pattern at an indefinite period means transferring the embossed pattern to the FRP surface continuously or discontinuously at an arbitrary interval.

The present invention has been made in view of such circumstances, and an object thereof is to provide a continuous manufacturing method of an FRP with an embossed pattern which can solve the problems of the prior art. Is. That is, there is a problem related to sliding as in the case of the die hole inner surface sheet interposition method, and occurrence of resin impregnation unevenness as in the case of the base material interlayer sheet interposition method and reusability of the peelable sheet-like body after peeling. FRP with embossed pattern can be continuously manufactured without any problems, has higher productivity compared to the batch method, and can continuously form FRP with embossed pattern. It is intended to provide a method.

[0008]

In order to achieve the above object, the method for continuously producing an embossed fiber reinforced plastic (FRP) according to the present invention has the following constitution. That is, in the method according to claim 1, the fiber base material impregnated with the resin is drawn into a heating die, and the resin in the fiber base material is semi-cured while running in the die axial direction, and the semi-cured material after passing through the die is used. Embossing characterized in that after the embossed pattern is transferred to the surface of the fiber-reinforced plastic in the cured state with an imprinting machine that forms the embossed pattern, it is heated in a heating furnace to bring it into the cured state. It is a continuous production method of patterned fiber reinforced plastic. The method according to claim 2 is the method for continuously producing a fiber-reinforced plastic with an embossed pattern according to claim 1, wherein the embossed pattern is transferred in a fixed cycle or an indefinite cycle.

[0009]

The continuous manufacturing method of the FRP with the embossed pattern according to the present invention, as described above, draws the resin-impregnated fiber base material into the heating die, and runs the resin in the fiber base material while running in the die axial direction. Is semi-cured, and the embossed pattern is transferred to the surface of the fiber-reinforced plastic in the semi-cured state after passing through the die with an imprinting machine that forms the embossed pattern, and then heated in a heating furnace. Since it is set to a cured state, problems with sliding such as in the case of the die hole inner surface sheet interposing method, and occurrence of resin impregnation unevenness and peeling after peeling as in the base material interlayer sheet interposing method The FRP with embossed pattern can be continuously manufactured without the problem that the reusable sheet-like material cannot be reused, and the productivity is superior to the batch method, and the embossed pattern can be formed at irregular intervals. It can become.

That is, the cured product is an FRP with an embossed pattern, which can be continuously obtained, so that the FRP with an embossed pattern can be continuously produced. It has excellent properties.

Further, the transfer of the embossed pattern is not carried out by the peelable sheet-like material as in the case of the method of interposing the sheet on the inner surface of the die hole or the method of interposing the base material interlayer sheet, but the fiber is reinforced in a semi-cured state after passing the heating die. For the surface of plastic,
Since it is performed by transferring the embossed pattern with a shaping machine that forms the embossed pattern, there are problems with sliding such as in the case of the die hole inner surface sheet interposing method, and in the case of the base material interlayer sheet interposing method. It is possible to form an embossed pattern in an indefinite cycle by adjusting the transfer cycle (time interval between transfer points) of the above-mentioned shaping machine without causing the problem that the releasable sheet-like body cannot be reused. it can.
Furthermore, since it is not necessary to directly inject the resin into the heating die, the occurrence of uneven resin impregnation unlike the case of the intervening base material sheet method does not occur.

In the present invention, as the fiber substrate, a continuous filament fiber substrate or a sheet fiber substrate can be used. The continuous filament fiber base material generally refers to glass roving, but may be made of another material including carbon fiber or aramid fiber. Examples of the sheet-shaped fiber base material include a continuous strand mat made of a glass fiber material, a chopped strand mat, and a polyester mat. Further, a surfacing mat may be additionally provided on the outer surface of the sheet-shaped fiber base material.

Examples of the resin with which the fiber base material is impregnated include thermosetting resins such as unsaturated polyester resins and epoxy resins which can be continuously drawn and drawn. FR
For the content of fibers in P, see FRP with embossed pattern
25 in terms of moldability (pullability, transfer characteristics, etc.) during manufacturing and the characteristics (strength, etc.) of the FRP with embossed pattern itself.
It is desirable to be ~ 85%. If it is less than 25%, the moldability is excellent, but the strength of FRP is low, and if it exceeds 85%, the strength of FRP is high, but the moldability tends to be low. As a shaping machine,
A small direct pressure press with an embossed pattern on the surface is desirable.

[0014]

[Embodiment] FRP with embossed pattern according to an embodiment of the present invention
FIG. 1 shows a flow of the continuous manufacturing method of, and FIG. 1 is a perspective view showing a process of transferring an embossed pattern and a heating process in the flow. As shown in FIG. 1, a predetermined amount of the fiber base material 1 is arranged in the drawing direction, is introduced into the resin tank 3, and is impregnated with the resin 2.
Then, the fiber base material 4 impregnated with the resin 2 is pulled out from the resin tank 3 by the pull-out drive unit 11 and introduced into the heating die 5, where the resin in the fiber base material 4 is semi-cured, and The semi-cured FRP 7 is led out from the heating die 5. At this time, it is suitable that the drawing speed is 0.3 to 1.5 m / min and the heating die length is about 300 to 1200 mm. Although the resin in the fiber base material 4 is cured in the heating die 5,
By adjusting the heating temperature of the heating die 5, the resin can be semi-cured.

Next, as shown in FIGS. 1 and 2, the FRP 7 in a semi-cured state after being drawn out from the heating die 5 is guided to a shaping machine 10 having an embossed pattern, and the shaping machine 10 causes the FRP 7 to move.
The embossed pattern 13 is transferred to the surface of 7. Then, the FRP 7 after the transfer of the embossed pattern is guided to the heating furnace 6, where it is subjected to after-curing (heat curing) to be in a cured state. Then, the FRP 8 with the embossed pattern after the thermosetting is cut into a desired length by a cutter 12. In this way, the FRP with a predetermined embossed pattern is successively obtained.

When the embossed pattern is transferred by the shaping machine 10, by adjusting the transfer cycle of the shaping machine 10,
It is also possible to easily form the embossed pattern 13 in an irregular cycle. That is, not only the FRP with the fixed-cycle embossed pattern, but also the FRP with the non-fixed-cycle embossed pattern can be easily and continuously obtained. As the heating die, instead of the above heating die 5,
A guide for forming a desired cross-sectional shape and a high-frequency heating furnace following the guide may be used. In FIGS. 1 and 2, reference numeral 9 indicates a shaping machine driving unit.

[0017]

EFFECTS OF THE INVENTION According to the continuous manufacturing method of embossed fiber reinforced plastic (FRP) according to the present invention, there are problems with sliding as in the case of the conventional die hole inner surface sheet intercalation method, and the base material layer FRP with embossed pattern can be continuously produced without the problem of uneven resin impregnation and the inability to reuse the releasable sheet-like material after peeling as in the case of the sheet intervening method. In addition to the FRP with a fixed-cycle embossed pattern, the FRP with a fixed-cycle embossed pattern can be easily obtained in succession.

[Brief description of drawings]

FIG. 1 is a diagram showing a flow of a continuous manufacturing method of an FRP with an embossed pattern according to an embodiment of the present invention.

FIG. 2 is a perspective view showing a transfer and heating status of an embossed pattern according to an embodiment of the present invention.

[Explanation of symbols]

1--fiber base material, 2--resin, 3--resin tank, 4--resin-impregnated fiber base material, 5--heating die, 6--heating furnace, 7--
Semi-cured FRP, 8--FR with embossed pattern after heat curing
P, 9--Shaping machine drive, 10--Shaping machine, 11--Pulling drive, 12--Cutter, 13--Embossing pattern.

 ─────────────────────────────────────────────────── ─── Continuation of the front page (72) Inventor Takaho Fujiura 1-5-5 Takatsukadai, Nishi-ku, Kobe-shi, Hyogo Kobe Steel Works, Ltd. Kobe Research Institute

Claims (2)

[Claims] 1. A fiber base material impregnated with a resin is drawn into a heating die, and the resin in the fiber base material is semi-cured while traveling in the die axial direction, and the fiber is reinforced in a semi-cured state after passing through the die. A fiber reinforced plastic with an embossed pattern, characterized in that the embossed pattern is transferred to the surface of the plastic by a shaping machine that forms the embossed pattern, and then heated in a heating furnace to be cured. Continuous manufacturing method. 2. The method for continuously producing a fiber-reinforced plastic with an embossed pattern according to claim 1, wherein the embossed pattern is transferred in a fixed cycle or an indefinite cycle.