JPH0872186A - Fiber reinforced resin unit plate, and manufacture thereof - Google Patents

Abstract

PURPOSE: To provide an FRP unit plate in which a uniform resin layer is formed on the surface of a unit plate and which has excellent external appearance and is scarcely stained and has excellent weather resistance. CONSTITUTION: Semicured SMC is laminated, nonwoven fabric is laminated on the front surface side of the SMC reinforced resin layer of a base material layer, woven fabric of glass fiber or carbon fiber or continuous fiber mat is laminated on the intermediate layer of the SMC reinforced resin layer, heated, and pressure molded to obtain a fiber reinforced resin unit plate.

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 fibers or carbon fibers into a resin. The present invention relates to a unit plate used for a container, a panel type tank (water tank, hot water storage tank, chemical solution tank, etc.), a cooling tower, etc., and a manufacturing method thereof.

[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.
This FRP unit plate is obtained by stacking semi-cured SMC (sheet molding compound) and heating and press-molding, and it is said that rust and corrosion do not occur as compared with a unit plate made of steel plate. Have advantages. But FR
When the P 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 adhere to the gaps between the fibers and the resin, resulting in a marked loss of appearance. In addition, there is a problem that the life of the FRP unit plate may be significantly shortened from the gap.

[0003]

Therefore, in order to suppress the exposed protrusion on the surface, a woven cloth of glass fibers or a continuous fiber mat is laminated on the surface side of the SMC reinforced resin layer forming the base material layer, and heating, Some are pressure molded. But SM
A glass fiber woven cloth or continuous fiber mat is laminated on the surface side of the C-reinforced resin layer, but since the glass fiber woven cloth or continuous fiber mat forms the surface layer of the unit plate, the surface gloss is reduced, and There are inconveniences such as visually observing the pattern of glass fiber. Further, during press molding, glass fibers may be cut, wrinkles may be generated, fibers may be floated or partial impregnation may occur. Further, since the glass fiber on the surface is easily exposed, it is easily soiled, and there is a problem in weather resistance and water resistance.

The present invention has been made in view of the above problems and has a good impregnation property of a resin component into a surface layer of a unit plate, a uniform resin layer formed on the surface, and a good appearance, and It is an object of the present invention to provide an FRP unit plate that is resistant to stains and has excellent weather resistance, and a method for manufacturing the same.

[0005]

[Means for Solving the Problems]

[Invention of Claim 1] The present invention relates to a fiber-reinforced resin unit plate obtained by laminating semi-cured SMC, heating and press-molding, and at least one of the SMC-reinforced resin layers forming a base material layer. The non-woven fabric is laminated on the surface side of the
A fiber-reinforced resin unit plate, comprising a woven fabric of glass fibers or carbon fibers or a continuous fiber mat laminated on an intermediate layer of the MC-reinforced resin layer.

Here, the semi-cured SMC (sheet molding compound) means, for example, thermosetting resin such as unsaturated polyester resin, vinyl ester resin, epoxy resin or phenol resin, filled with calcium carbonate or the like. Made by impregnating a chopping fiber of roving glass or other glass fiber or chopping fiber of carbon fiber with a resin compound containing a curing agent, a curing agent, a thickening agent such as magnesium oxide, etc. It is a so-called aged sheet-shaped molding material in which the resin is thickened to eliminate stickiness in order to improve handleability.

In the present invention described above, a woven fabric of glass fibers or carbon fibers or a continuous fiber mat is formed into a semi-cured SMC.
By interposing between the (sheet molding compound) and the SMC and stacking them, the sheet is disposed not as a surface layer of the SMC reinforced resin layer but as an intermediate layer of the SMC reinforced resin layer. During molding, the fibers of the layer are prevented from being exposed on the surface of the unit plate.

Further, at least one surface side of the SMC reinforced resin layer forming the base material layer (usually the outer surface is mainly).
By laminating the non-woven fabric on the non-woven fabric, the exposure of the chopping fiber or the like of the roving glass contained in the SMC is suppressed by the non-woven fabric, and the resin component of the SMC reinforced resin layer is impregnated in the non-woven fabric and the outside of the non-woven fabric layer That is, the surface is permeated and exudes, and a thin surface resin layer made of a resin component is formed outside the nonwoven fabric layer, that is, on the surface.

Although the non-woven fabric used in the present invention is not particularly limited, it is usually a non-woven fabric of glass fiber or polyester fiber. Normally, the basis weight is 20 to 60 g / m
² The surface layer of a conventional fiber-reinforced resin unit plate has a large basis weight and is laminated with a glass fiber woven fabric or a continuous fiber mat which is difficult to impregnate with a resin, but this has a small basis weight and is easily impregnated. By replacing with a non-woven fabric such as glass fiber or polyester fiber, the resin component is satisfactorily impregnated and a resin layer is formed on the surface, so that the surface is glossy, the appearance is improved, and the weather resistance is improved.

The non-woven fabric is a paper-like thin non-woven fabric in which long fiber polyester fibers are bonded to each other with an acrylic resin, and the non-woven fabric is strong and hard to be cut during molding.
Preferably 0.05 to 0.5 on the surface of the molded product (unit plate)
It is possible to form a resin layer having a uniform thickness of about mm. The diameter of the long fibrous polyester fiber is about 15 to 19 μm, the basis weight is 20 to 60 g / m ² , and the thickness is 0.1 to 0.
There is a 4 mm one.

As described above, a nonwoven fabric is laminated on at least one surface side of the SMC reinforced resin layer forming the base material layer, and the intermediate layer of the SMC reinforced resin layer is made of glass fiber or carbon fiber woven fabric or By laminating the continuous fiber mat, the occurrence of cutting, embossing, wrinkling, and partial impregnation of glass fiber, which has been conventionally seen, is eliminated, and a uniform resin layer is formed on the surface.

[Invention of Claims 2 and 3] The present invention relates to a fiber-reinforced resin unit plate obtained by laminating semi-cured SMC, heating and press-molding, and strengthening SMC which constitutes a base material layer. A fiber-reinforced resin unit plate, characterized in that a high-fluidity resin compound is applied to the surface side of a resin layer and then a nonwoven fabric is laminated. Such a unit plate is a semi-cured SMC.
In order to manufacture a fiber-reinforced resin unit plate by laminating, heating and pressure-molding, a high-fluidity resin compound is applied to the surface side of the SMC-reinforced resin layer forming the base material layer, and then a non-woven fabric is laminated. Is obtained by

The unit plate according to the present invention is a semi-cured S.
When MC (sheet molding compound) is laminated and heated and pressed, SM is laminated to form a base material layer
Since the non-woven fabric is laminated after applying the high-fluidity resin compound on the surface side of the C-reinforced resin layer, the high-fluidity resin compound easily impregnates / penetrates into the non-woven fabric and permeates / exudes the non-woven fabric layer to form this non-woven fabric. On the outside or surface of the layer,
A uniform surface layer is formed by the resin component.

On the other hand, when the high fluidity resin compound is not applied, only the permeation of the base material SMC by the unsaturated polyester resin is carried out. Therefore, when the fluidity of the SMC is poor, the non-woven fabric may be cut or the resin may be impregnated poorly. A uniform resin layer is easily formed, which may impair the appearance. Further, when the amount of the resin component that permeates is small, the desired thickness of the surface resin layer may not be obtained, and the fiber may be exposed.In such a surface state, it may occur due to deterioration of the surface resin layer. Dust adheres to the exposed surface of the fiber or the exposed fiber with poor impregnation, the surface is contaminated, the appearance is deteriorated, and the weather resistance is not good.

The high-fluidity compound used in the present invention is a compound having a higher fluidity than the SMC reinforced resin layer forming the base material layer, and more easily penetrating into the nonwoven fabric than the SMC forming the base material layer. It is essential. For example, 80 parts by weight of unsaturated polyester resin and 20 parts by weight of low-shrinkage resin are combined as a main material resin, and the main material resin 100
It is preferable to mix a filler such as calcium carbonate in an amount of 60 parts by weight or less with respect to parts by weight. The blending amount of the filler is appropriately adjusted by looking at the viscosity of the resin compound. The viscosity may be such that the resin compound can permeate or impregnate the non-woven fabric, but as a compounding example of the high fluidity compound, 80 parts by weight of unsaturated polyester resin, 20 parts by weight of low shrinkage resin, curing agent (t-butyl peroxybenzoate) ) 1 part by weight and a filler (calcium carbonate) 15 to 60 parts by weight.

As the non-woven fabric used in the present invention, the same non-woven fabric as used in the invention according to claim 1 can be used.

A woven cloth of glass fibers or carbon fibers or a continuous fiber mat is laminated on the intermediate layer of the SMC reinforced resin layer, and a high-fluidity resin compound is formed on the surface side of the SMC reinforced resin layer forming the base layer. The unit plate in which the non-woven fabric is laminated after applying is has a better appearance and excellent weather resistance.

[0018]

【Example】

Example 1-Invention of Claim 1 First, a resin compound having the following composition was impregnated into chopping fiber (30% by weight) of roving glass to obtain a semi-cured SMC.

Unsaturated polyester resin 80 parts by weight Low shrinkage resin (polystyrene solution) 20 parts by weight Curing agent (t-butylperoxybenzoate) 1 part by weight Internal release agent (zinc stearate) 5 parts by weight Filler (carbonic acid) Calcium) 100 parts by weight Pigment 5 parts by weight Thickener (magnesium oxide) 1 part by weight

Next, 6 sheets of the above SMC (width 1 per sheet
m × length 2 m × thickness 2 mm, 6 kg) and prepare SM
A continuous fiber mat of glass fibers (400 g / m ² ) is sandwiched between the SMC substrate layers in which three Cs are laminated, and a glass fiber nonwoven fabric (60 g
/ M ² ) and place it on the die of the press machine.
The upper mold was closed, and heated at 130 ° C. and 50 kg / cm ² for about 7 minutes and pressure-molded to remove the mold. Good surface gloss,
A fiber reinforced resin unit plate having a beautiful appearance was obtained.

[Comparative Example 1] On the other hand, a conventional unit having a continuous fiber mat of glass fibers laminated on the surface of SMC is heated and pressure-molded under the same conditions as in Example 1 to form a fiber-reinforced resin unit plate. Got

The unit plate of Example 1 obtained had good moldability and did not cause cutting, embossing, wrinkles, or impregnation defects of the glass fiber in the surface layer, but the unit plate of Comparative Example 1 partially generated. .

In the unit plate of Example 1, the glass fiber pattern (exposed) on the surface was invisible, and the surface resin layer provided a good gloss, while the glass of Comparative Example 1 had glass fibers. Is visually observed and the gloss is inferior.

The glass of Example 1 did not expose the glass fiber even when exposed to wind and rain, and showed superior weather resistance to that of Comparative Example 1.

Example 2-Invention of Claims 2 and 3 First, a resin compound having the following composition was impregnated into chopping fiber (30% by weight) of roving glass to obtain a semi-cured SMC.

Unsaturated polyester resin 80 parts by weight Low shrinkage resin (polystyrene solution) 20 parts by weight Curing agent (t-butylperoxybenzoate) 1 part by weight Internal release agent (zinc stearate) 5 parts by weight Filler (carbonic acid Calcium) 100 parts by weight Pigment 5 parts by weight Thickener (magnesium oxide) 1 part by weight

Next, 6 sheets of the above SMC (width 1 per sheet
m × length 2 m × thickness 2 mm, 6 kg), and the SM
On the surface of the C substrate layer, a high fluidity resin compound having the following composition was applied by spraying.

Unsaturated polyester resin 80 parts by weight Low shrinkage resin (polystyrene solution) 20 parts by weight Curing agent (t-butylperoxybenzoate) 1 part by weight Filler (calcium carbonate) 30 parts by weight Pigment 5 parts by weight

Further, a polyester fiber non-woven fabric (60 g / m 2) is applied to the surface coated with the above-mentioned high fluidity resin compound.
² ) were piled up and placed on the die of the press machine, the upper die was closed, and heating and pressure molding were carried out at 130 ° C. and 50 kg / cm ² for about 7 minutes to remove the die. A fiber-reinforced resin unit plate (water tank panel) having a good surface gloss and a beautiful appearance was obtained.

Comparative Example 2 On the other hand, a unit made of fiber reinforced resin was prepared by heating and press molding under the same conditions as in Example 2 except that the high fluidity resin compound was not applied to the surface of the SMC substrate layer. I got a plate.

The obtained unit plate of Example 2 did not cause fiber breakage or impregnation failure in the surface layer, formed a resin layer (0.05 to 3 mm) that penetrated the nonwoven fabric on the surface, and had good gloss. On the other hand, in Comparative Example 2, impregnation failure partially occurred, and a resin layer was hardly formed on the surface,
The gloss is poor. Further, since the surface resin layer is present, the non-woven fabric is not exposed until the resin layer is deteriorated and becomes thin, and excellent weather resistance is exhibited, whereas in Comparative Example 2, the resin layer is not formed on the surface. Therefore, the nonwoven fabric was exposed by the wind and rain, and the exposed nonwoven fabric was contaminated by dust and the like, and the surface was darkened.

[0032]

【The invention's effect】

[Invention of Claim 1] A nonwoven fabric is laminated on at least one surface side of an SMC reinforced resin layer forming a base material layer, and a glass fiber or carbon fiber woven fabric or an intermediate layer of the SMC reinforced resin layer is formed. By laminating the continuous fiber mat, the cutting, embossing, wrinkling, and partial impregnation of the glass fiber, which have been seen in the past, are eliminated, a uniform resin layer is formed on the surface, and the surface has a glossy appearance. Is improved, the fibers are less likely to be exposed, stains are less likely to occur, and weather resistance is improved. Since the quality of the unit plate is improved and the product yield is improved, good productivity can be expected in the molding cycle, mass production, etc., which is extremely useful.

[Invention of Claims 2 and 3] Since the non-woven fabric is impregnated beforehand with the high-fluidity resin compound, there is no occurrence of fiber cutting or impregnation failure as has been seen in the past.
The resin layer is uniformly formed on the surface of the molded product, the surface has gloss, and the appearance at the time of molding is remarkably improved, and the fibers are less likely to be exposed even when exposed to wind and rain, and are less likely to stain and weather resistance is improved. Since the quality of the unit plate is improved and the product yield is improved, good productivity can be expected in the molding cycle, mass production, etc., which is extremely useful.

Continuation of the front page (51) Int.Cl. ⁶ Identification code Office reference number FI technical display location B32B 17/04 Z // B29K 101: 10 105: 08 B29L 9:00

Claims (3)

[Claims] 1. In a fiber-reinforced resin unit plate obtained by laminating semi-cured SMC and heating and press-molding, a nonwoven fabric is laminated on at least one surface side of the SMC-reinforced resin layer forming a base material layer. In addition, a fiber-reinforced resin unit plate, characterized in that a woven cloth of glass fibers or carbon fibers or a continuous fiber mat is laminated on the intermediate layer of the SMC reinforced resin layer. 2. In a fiber-reinforced resin unit plate obtained by laminating semi-cured SMC and heating and press-molding, a high-fluidity resin compound is provided on the surface side of the SMC-reinforced resin layer which is a base material layer. A fiber reinforced resin unit plate, which is obtained by laminating non-woven fabrics after applying. 3. When a semi-cured SMC is laminated and heated and pressure-molded to manufacture a fiber-reinforced resin unit plate, a high-fluidity resin is provided on the surface side of the SMC-reinforced resin layer forming a base material layer. A method for producing a fiber-reinforced resin unit plate, comprising laminating non-woven fabrics after applying a compound.