JPH0858008A - Fiber reinforced molded article and production thereof - Google Patents

Abstract

PURPOSE: To obtain a tough and lightweight fiber reinforced molded article having a beautiful surface by laminating a specific number of reinforcing fiber fabric materials so as to closely bond them to the rear surface of a transparent resin layer to form a reinforcing fiber layer and applying a fixing resin to the surface of the reinforcing fiber layer to infiltrate the same into the fiber layer before curing. CONSTITUTION: A transparent resin is molded into a desired shape by usual thermal molding to form a transparent resin layer 2. Next, a specific number of reinforcing fiber fabric materials having a slightly large area are laminated by using a jig so as to be closely bonded to the rear surface of the transparent resin layer 2 to form a reinforcing fiber layer 3. Subsequently, a room temp. curable fixing resin is applied to the surface of the reinforcing fiber layer 3 to be infiltrated into the fiber layer 3 and the impregnated fiber layer is allowed to stand at room temp. for a predetermined time to be cured to form a fixing resin layer 4. Thereafter, the reinforcing fiber fabric material layer protruding from the outer edge of the transparent resin layer 2 is cut and the edge part thereof is ground by sand paper to complete a fiber reinforced molded article 1.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a fiber-reinforced molded article which is tough, lightweight and has a beautiful surface, and a method for producing the same.

[0002]

2. Description of the Related Art FRP is one of the conventional technologies of this kind.
(Fiber reinforced plastic) is well known. This F
Glass fibers and carbon fibers are mainly used as the reinforcing fibers of RP, and when these are used as continuous fibers, the matrix (matrix material) is a thermosetting resin such as unsaturated polyester resin or epoxy resin. Is often used.

As this molding method, a hand lay-up method is well known, which is one in which a woven fabric material of reinforcing fibers is laminated on a molding die to which a release agent is applied in advance. A matrix resin is applied and impregnated on this, the resin is cured, and then the molded product is released from the mold.

In order to make the surface smooth,
Prior to molding, it is also practiced to apply a matrix resin on the mold in advance (gel coating) and then mold.
Alternatively, in order to make the surface beautiful, as shown in FIG. 3, the FRP 5 is backed up to the transparent resin 2 such as acrylic resin.

[0005]

However, it is difficult to say that the conventional FRP as described above is rich in aesthetic sense even if the surface is gel-coated and smooth, and normally, paint or the like is applied on top of it. Often applied to produce products.

Most of transparent resin backed up with FRP are formed by a spray-up method, which is a method in which a bundle of reinforced fibers (roving) is cut at the tip of a spray gun and mixed with the resin. It is formed by spraying and coating on the back surface of the transparent resin, followed by curing. As described above, since the cut roving is used, there is a problem in that strength and rigidity are reduced as compared with those formed by the hand layup method.

Further, the conventional molding method has a problem that it is difficult to confirm the inclusion of air bubbles and the twisting of fibers during molding until the mold is removed.

The present invention has been made in view of the above problems and circumstances, and an object thereof is to provide a tough and lightweight fiber-reinforced molded article having a beautiful surface and a method for producing the same.

[0009]

In order to achieve the above object, the means for forming a fiber reinforced molded article according to claim 1 is to provide a reinforced fiber on the back surface of a transparent resin layer molded in a predetermined shape using a transparent resin. A predetermined number of woven fabric materials are laminated so as to adhere to the back surface of the transparent resin layer to form a reinforcing fiber layer, and a fixing resin is applied and impregnated on the surface of the reinforcing fiber layer and then cured to cure the fixing resin layer. Is formed.

The means for producing the fiber-reinforced molded article according to claim 2 is that the transparent resin layer back surface molded with a transparent resin into a predetermined shape and the reinforcing fiber woven material on the transparent resin layer back surface. A predetermined number of layers are laminated so as to be in close contact with each other to form a reinforcing fiber layer, and then a fixing resin is applied and impregnated on the surface of the reinforcing fiber layer and then cured to form a fixing resin layer.

According to a third aspect of the present invention, there is provided a fiber-reinforced molded body, wherein the back surface of the transparent resin layer molded with a transparent resin into a predetermined shape is impregnated with a fixing resin to form a reinforcing fiber woven material. The FRP layer is formed by stacking a predetermined number of layers so as to be in close contact with the back surface of the resin layer and then curing the layers.

Further, the means of the method for producing a fiber-reinforced molded article according to claim 4 is a woven fabric material of reinforcing fibers in which a back surface of a transparent resin layer molded with a transparent resin is impregnated with a fixing resin. Is laminated on the rear surface of the transparent resin layer in a predetermined number and then cured to form an FRP layer.

[0013]

In the fiber-reinforced molded product constructed as described above, the reinforcing fiber layer can be visually observed through the transparent resin layer on the surface. Therefore, the texture of the reinforcing fiber woven material can be visually observed as it is, and the texture has a unique beauty as a beautiful pattern.

Further, the fixing resin reaches the transparent resin layer by being applied to the surface of the reinforcing fiber layer and then impregnated between the fibers of the reinforcing fiber woven material. Then, by hardening the fixing resin, the reinforcing fiber layer is bonded and fixed to the transparent resin layer.

On the other hand, when a woven fabric material of reinforcing fibers is impregnated with a fixing resin in advance, it can be attached to the transparent resin layer as it is. By stacking and curing a predetermined number of these, the FRP layer is formed on the back surface of the transparent resin layer.

As described above, the fiber-reinforced molded article is obtained by sequentially forming the reinforced fiber layer and the fixing resin layer on the back surface of the transparent resin layer formed first, or by forming the FRP layer. The shape of the transparent resin layer is finished as it is.

Further, in the past, F produced from a molding die was used.
Although the RP is removed from the mold, in the present invention, the transparent resin layer that functions as a mold is integrated with the reinforcing fiber layer and the fixing resin layer or the FRP layer. Further, at the time of molding, the state of the reinforcing fiber layer can be visually observed through the transparent resin layer, so that twisting of the reinforcing fiber, inclusion of bubbles, and the like can be confirmed.

[0018]

EXAMPLE An example of the fiber-reinforced molded article 1 of the present invention is as follows.
As shown in FIG. 1, on the back surface of the transparent resin layer 2 formed in a trapezoidal shape having a recessed portion in the upper surface using a transparent resin, several pieces of reinforcing fiber woven material are adhered to the back surface of the transparent resin layer 2. The reinforcing fiber layer 3 is laminated to form a fixing resin layer 4 on the surface of which the fixing resin is applied, impregnated and then cured.

In this embodiment, the transparent resin layer 2 is formed in a trapezoidal shape having a concave portion in the middle of the upper surface, but the shape of the transparent resin layer 2 is not limited to this, and it is desired. It can be formed into various shapes. The transparent resin forming the transparent resin layer 2 is also not particularly limited, but it is preferable to use a transparent thermoplastic resin having excellent moldability. As this transparent resin, acrylic resin,
Examples thereof include polycarbonate resin, vinyl chloride resin, styrene resin and the like.

Further, as the reinforcing fiber, glass fiber, etc.,
Various fibers can be used, but high strength, high elasticity,
It is desirable to use carbon fiber in terms of good luster, beauty and fineness of texture. Since this carbon fiber has higher elasticity than glass fiber, the number of layers can be reduced and the weight can be reduced. Further, due to its high elasticity, it is less likely to be cracked or broken by impact or strain stress, and therefore can be used for a movable member. Further, the weaving method of the reinforcing fiber woven material is not particularly limited, and the number of the woven material laminated on the transparent resin layer 2 can be freely selected from one to several or more depending on the application. it can.

As the fixing resin, a room temperature curable thermosetting resin is desirable, and a polyester resin, a urethane resin, or the like is used so that it can be more easily applied and impregnated between the reinforcing fibers. Before curing, it is preferable that it is liquid and has an appropriately low viscosity.

On the other hand, regarding the method for producing the fiber-reinforced molded body 1 of the present invention, for example, first, a transparent resin is used,
The transparent resin layer 2 is formed into a desired shape by ordinary thermoforming or the like. Next, on the back surface of the transparent resin layer 2, a woven fabric material of reinforcing fibers having an area slightly larger than that of the back surface of the transparent resin layer 2,
A reinforced fiber layer 3 is formed by laminating a predetermined number of layers using a jig or the like so as to be in close contact with the back surface of the transparent resin layer 2. Then, the surface of the reinforcing fiber layer 3 is coated with and impregnated with a room-temperature curing type fixing resin before curing. Then, the fixing resin is left to stand for a predetermined time at room temperature to cure, and the fixing resin layer 4 is formed. Then, the reinforcing fiber woven material protruding from the outer edge of the transparent resin layer 2 is cut, and the edge portion is cut with sandpaper or the like. The fiber-reinforced molded body 1 is completed by polishing and cleaning.

On the other hand, another embodiment of the fiber reinforced molded article 1 of the present invention is, as shown in FIG. 2, a transparent resin layer 2 back surface formed by using a transparent resin and having a trapezoidal shape having a concave portion in the upper middle portion. Further, a predetermined number of reinforcing fiber woven materials impregnated with a fixing resin in advance are laminated so as to adhere to the back surface of the transparent resin layer 2 and then cured to form the FRP layer 5.

In this embodiment as well, the transparent resin layer 2 is formed into a trapezoidal shape having a concave portion in the upper middle portion.
Similar to the above, the shape of the transparent resin layer 2 is not limited to this, and can be formed into various desired shapes. Further, a transparent resin used for the fiber-reinforced molded body 1,
The woven fabric material of the reinforcing fiber and the fixing resin may be the same as described above. Further, since the continuous fiber woven material is used, a tougher material can be obtained as compared with the one formed by the conventional spray-up method.

Further, regarding this manufacturing method, for example,
First, a transparent resin layer 2 is formed by molding a transparent resin into a desired shape by ordinary thermoforming or the like. Next, the back surface of the transparent resin layer 2 was impregnated with a room temperature curing type fixing resin in advance, and a reinforced fiber woven material having a slightly larger area than the back surface of the transparent resin layer 2 was treated with care so that no void could be formed. A predetermined number of layers are laminated using a tool or the like so as to be in close contact with the back surface of the transparent resin layer 2. Then, after leaving it for a predetermined time at room temperature to cure the fixing resin to form the FRP layer 5, the FRP protruding from the outer edge of the transparent resin layer 2 is cut, and the edge portion is polished with sandpaper or the like to clean the fiber reinforced. The molded body 1 is completed.

The fiber-reinforced molded body 1 obtained as described above can be used for various parts, but since the unique beauty of the reinforced fiber woven material can be experienced with depth through the transparent resin layer on the surface, the surface material Can be used alone or as a combination member. For example, helmets, attache cases, bathtubs, sports equipment, panels, various covers,
It can be used for various things such as nameplates, signboard crafts, etc.

[0027]

Since the present invention is constructed as described above, it has the following effects.

Since the texture of the reinforced fiber woven material has a unique beauty as a pattern through the transparent resin layer on the surface, it has a remarkably aesthetic feeling as compared with the conventional FRP or a transparent resin backed up with FRP. Rich. Therefore,
It can be used as a product without applying any paint.

Further, since the shape of the transparent resin layer to be first molded is finished, various shapes can be freely obtained by changing the shape of this transparent resin layer.

At the time of molding, since twisting of reinforcing fibers, inclusion of bubbles, and the like can be confirmed, the defective rate of the finished product can be significantly reduced.

Further, since it is reinforced by continuous fibers of reinforcing fibers, a tough product can be obtained, and since it is possible to make the product thinner than other products requiring the same strength, it is possible to reduce the weight. .

Furthermore, since the finishing is basically done by hand, no sophisticated equipment or equipment is required other than forming the transparent resin layer into a predetermined shape. Therefore, various depreciation costs are not required, and the initial cost can be reduced. In addition, since it can be manufactured from a single product, it can be sufficiently adapted to small-quantity multi-product production.

[Brief description of drawings]

FIG. 1 is a cross-sectional view showing an embodiment of the fiber-reinforced molded product of the present invention.

FIG. 2 is a sectional view showing another embodiment of the fiber-reinforced molded product of the present invention.

FIG. 3 is a sectional view of a main part showing a conventional example.

[Explanation of symbols]

 1 Fiber Reinforced Molded Body 2 Transparent Resin Layer 3 Reinforced Fiber Layer 4 Fixing Resin Layer

Claims (4)

[Claims] 1. A reinforcing fiber layer is formed by laminating a predetermined number of reinforcing fiber woven materials on the back surface of a transparent resin layer formed of a transparent resin into a predetermined shape so as to be in close contact with the transparent resin layer back surface. A fiber reinforced molded article, characterized in that a fixing resin is applied and impregnated on the surface of the reinforcing fiber layer and then cured to form a fixing resin layer. 2. A reinforcing fiber layer is formed by laminating a predetermined number of reinforcing fiber woven materials on the rear surface of the transparent resin layer formed of a transparent resin in a predetermined shape so as to be in close contact with the rear surface of the transparent resin layer, Next, apply a fixing resin to the surface of the reinforcing fiber layer,
A method for producing a fiber-reinforced molded product, which comprises impregnating and then curing to form a fixing resin layer. 3. After laminating a predetermined number of woven fabric materials of reinforcing fibers impregnated with a fixing resin on the back surface of the transparent resin layer formed of a transparent resin in a predetermined shape so as to be in close contact with the back surface of the transparent resin layer. A fiber-reinforced molded product, characterized by being cured to form an FRP layer. 4. A predetermined number of woven fabric materials of reinforcing fibers impregnated with a fixing resin are laminated on the back surface of a transparent resin layer formed of a transparent resin in a predetermined shape so as to be adhered to the back surface of the transparent resin layer. A method for producing a fiber-reinforced molded body, which comprises curing to form an FRP layer.