JPH0872185A - Unit plate made of fiber-reinforced resin - Google Patents

Abstract

PURPOSE: To manufacture a unit plate made of a fiber reinforced resin (FRP) in which weather resistance is improved and scarcely stained by laminating polyester nonwoven fabric adhered to polyester fiber with specific resin on a sheet molding compound (SMC) reinforced resin layer. CONSTITUTION: Polyester nonwoven fabric in which long fiber polyester fibers are adhered by acrylic resin is laminated at the outside of an SMC reinforced resin layer 2 of a base material layer. A uniform surface resin layer 4 normally having a thickness of 0.1-0.5mm is formed at the outside of the nonwoven fabric layer 3. The reinforced resin layer used in this case is manufactured by impregnating, for example, glass fiber, carbon fiber, etc., with resin compound in which filter, curing agent, etc., such as calcium carbonate is mixed with unsaturated polyester resin, vinyl ester resin, epoxy resin, etc. The diameter of the polyester fiber is normally about 15-19μm.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a fiber-reinforced resin unit plate (FRP unit plate), more specifically, a fiber-reinforced resin (FRP) material prepared by mixing glass fiber or carbon fiber into a resin. The present invention relates to a unit plate used for containers, panel tanks, cooling towers, etc.

[0002]

2. Description of the Related Art In recent years, FRP molded into various shapes as containers, panel tanks, cooling towers, etc.
An assembly of RP unit plates is often used.
The FRP unit plate has an advantage that rust and corrosion do not occur as compared with a unit plate made of a steel plate. However, when the FRP unit plate is used outdoors and its surface deteriorates due to sunlight or wind and rain, the reinforcing fibers are exposed on the surface, and contaminants and the like adhere to the gaps between the fibers and the resin, resulting in a poor appearance. In addition to being significantly impaired, F
There is a problem that the life of the RP unit plate may be significantly shortened.

[0003]

Therefore, the present applicant firstly laminated a woven fabric or a non-woven fabric on an intermediate layer outside the SMC reinforced resin layer forming the base material layer, and on the outer side of this intermediate layer, the resin-rich resin was applied. A unit plate made of fiber reinforced resin provided with a surface layer formed of the components has been proposed (Japanese Patent Application No. 5-256494). However, the non-woven fabric used in the fiber-reinforced resin unit plate has not been sufficiently studied, and since the non-woven fabric is easily cut, when the non-woven fabric is laminated on the SMC, the resin layer cannot be sufficiently formed. Or SM
The reinforcing fibers of the C base material may be exposed on the surface of the unit plate.
In addition, since the fibers are soft, that is, have no so-called rigidity, when the SMC base material and the non-woven fabric are superposed, the non-woven fabric is wrinkled,
Overlapping may occur and it may be difficult to form a uniform resin layer.

The present invention has been made in order to solve the above-mentioned problems, and by forming a more uniform resin layer on the surface of an SMC substrate through a specific nonwoven fabric, the weather resistance is improved. It is an object of the present invention to provide a unit plate made of FRP which is excellent in stain resistance and does not easily get dirty.

[0005]

According to the present invention, a polyester non-woven fabric in which long fiber polyester fibers are bonded to each other with an acrylic resin is laminated on the outer side of an SMC reinforced resin layer forming a base layer, and the outer side of the non-woven fabric layer. A fiber-reinforced resin unit plate having a surface resin layer formed thereon.

In the present invention, a specific non-woven fabric is laminated as a pressing body on an uncured SMC base material which becomes the above-mentioned SMC (sheet molding compound) reinforced resin layer and pressure-molded to form this non-woven fabric layer. On the outer side, that is, on the surface, a surface layer is uniformly formed from the SMC reinforced resin layer, which is exuded by passing through the nonwoven fabric and leaching out.

The SMC (sheet molding compound) reinforced resin layer used in the present invention is, for example, a thermosetting resin such as an unsaturated polyester resin, a vinyl ester resin, an epoxy resin or a phenol resin, a filler such as calcium carbonate, and a curing agent. It is produced by impregnating glass fiber or carbon fiber chop fiber or the like with a resin compound containing an agent or the like.

The non-woven fabric used in the present invention is obtained by adhering long-fiber polyester fibers to each other with an acrylic resin and forms a porous body, so that resin components such as unsaturated polyester resin of the SMC substrate are easily exuded. It is essential. A thin paper-like material is preferable, and a thin material that is less likely to wrinkle is suitable as long as cutting does not occur during molding. The diameter of the long fibrous polyester fiber is usually 15 to
It is about 19 μm. It is preferable that the basis weight is 20 to 60 g / m ² and the thickness is 0.1 to 0.4 mm. Since the non-woven fabric in which long-fiber polyester fibers are adhered to each other with an acrylic resin is used, the non-woven fabric is hard to be cut during molding and is strong, and the surface of the molded product (unit plate) is
It is possible to form a resin layer having a uniform thickness of about 0.5 mm.

FIG. 1 is an enlarged sectional view schematically showing a unit plate 1 according to the present invention. Reference numeral 2 is an SMC reinforced resin layer, reference numeral 3 is a non-woven fabric layer, and reference numeral 4 is a surface resin layer. This unit plate 1 is, as shown in FIG. 2, an uncured SMC base material 2a.
The non-woven fabric layer 3 is superposed on the above as a pressing body, and the upper mold 21 is closed and heated and pressed to form a surface resin layer by the resin component of the SMC reinforced resin layer exuded through the non-woven fabric layer 3. 4 can be formed and obtained.

[0010]

EXAMPLES Examples of the present invention will be described below, but the present invention is not limited to the following examples and can be appropriately modified and implemented within the scope of the gist of the present invention.

Unit plate for water tank (size: 1000 × 1
000 mm: weight 15 kg), a semi-cured SMC base material was first prepared from a resin compound having the following composition and 30% by weight of chopping fiber of roving glass.

Unsaturated polyester resin 80 parts by weight Low shrinkage resin 20 parts by weight Curing agent 1 part by weight Internal mold release agent (zinc stearate) 5 parts by weight Filler (calcium carbonate) 120 parts by weight Pigment 3 parts by weight

Next, the above SMC base material was cut into a predetermined size to form five layers, and a non-woven fabric of polyester fibers bonded to each other with an acrylic resin (manufactured by Unitika Ltd., trade name Spunbond SB-51, with unit weight). 25 g / m ² ) and then placed on the die of the press so that the non-woven fabric surface becomes the outer surface of the unit plate.

Molding is carried out at a mold temperature of 135 ° C. and a pressure of 50 kg.
Heating / pressurization was performed for 7 minutes under the condition of / cm ² . It was confirmed that the resin layer (thickness: about 0.3 mm) including the fiber layer of the non-woven fabric was formed almost uniformly on the surface of the obtained unit plate.

On the other hand, in the conventional unit plate using the non-woven fabric used in the present invention, the surface resin layer is likely to be unevenly formed, and particularly, the resin layer is thin or the non-woven fabric has a high density. Occurred. The surface gloss of these parts was reduced, and the nonwoven fabric was exposed in a relatively early time (about 500 hours) in a weather resistance accelerated test using a sunshine weather meter. In contrast,
The unit plate of the present invention has good gloss on the entire surface. Further, in the weather resistance accelerated test, no exposure of the nonwoven fabric was observed even after the exposure time of 2500 hours.

From the above results, the unit plate according to the present invention is
It can be seen that the non-woven fabric is uniformly laminated on the entire unit plate without cutting or wrinkling to form the surface resin layer.

[0017]

As described above, according to the present invention,
Since the polyester nonwoven fabric in which long fibrous polyester fibers are bonded to each other with an acrylic resin is interposed outside the SMC reinforced resin layer forming the base material layer, the exposure of the reinforced fibers to the substrate surface is completely suppressed. Furthermore, since a uniform surface resin layer having a thickness of about 0.1 to 0.5 mm can be formed on the outside of the nonwoven fabric layer, the surface gloss is excellent,
Even if the resin deteriorates due to long-term natural exposure, the fibers will not be exposed and will not be exposed, and sand and dust will not easily adhere.
It has excellent weather resistance, maintains a beautiful appearance and can withstand long-term use.

[Brief description of drawings]

FIG. 1 is an enlarged sectional view schematically showing a unit plate 1 of an example.

FIG. 2 is an explanatory view showing a method of manufacturing the unit plate 1 shown in FIG.

[Explanation of symbols]

 1 Unit Board 2 SMC Reinforced Resin Layer 3 Nonwoven Fabric Layer 4 Surface Resin Layer

Claims (1)

[Claims] 1. A polyester non-woven fabric in which long fiber polyester fibers are bonded to each other with an acrylic resin is laminated on the outer side of an SMC reinforced resin layer forming a base layer, and a surface resin layer is formed on the outer side of the non-woven fabric layer. A unit board made of fiber-reinforced resin.