JPH10286835A - Fiber-reinforced plastic molding and its manufacture - Google Patents

Abstract

PROBLEM TO BE SOLVED: To draw a pattern difficult to express by coating to obtain a smooth surface by providing a coating layer obtained by impregnating a cloth with pattern with transparent plastic on a surface of a fiber-reinforced plastic body material. SOLUTION: A body material 5 is formed by impregnating one layer or a plurality of layers of glass fiber with plastic. A substrate layer 6 formed on the material 5 is formed of white-colored plastic. A gel coating layer 7 made of transparent plastic and cloth 9 are laminated with a coating layer 8 impregnated with transparent plastic. Here, the layer 7 is formed to be thicker than the layer 8. The cloth 9 is formed by weaving polyester fiber, and a woodgrain pattern 2 is printed on a surface of the cloth 9 by a screen printing method. Thus, the pattern of the cloth transmits the transparent plastic to be expressed on the surface and further convexo-concave shape or wrinkle of the surface is prevented.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a fiber-reinforced plastic molded article having a pattern on its surface and a method for producing the same.

[0002]

2. Description of the Related Art Conventionally, to draw a pattern on the surface of a fiber-reinforced plastic molded product, a pattern is painted on a surface of a base material made of fiber-reinforced plastic, or a plastic sheet material on which the pattern is printed is attached. doing.

[0003]

However, when painting a pattern, it is not possible to employ a pattern which is difficult to express by painting, for example, a wood grain pattern. It is conceivable to use a sheet material on which a wood grain pattern is printed. However, when this sheet material is attached to a curved surface, wrinkles may occur.
In other words, a molded product whose surface must be formed smoothly, such as a bathtub, cannot use the sheet material, which is likely to cause wrinkles at a curved portion when applying the pattern.

The present invention has been made in order to solve such problems, and a fiber-reinforced plastic molded article capable of drawing a pattern which is difficult to express by painting so as to have a smooth surface, and a method of manufacturing the same. The purpose is to provide.

[0005]

A molded article made of fiber-reinforced plastic according to the present invention is provided with a coating layer formed by impregnating a transparent cloth with a patterned cloth on the surface of a fiber-reinforced plastic base material. It is.

According to the present invention, the surface of the fiber reinforced plastic base material is covered with a coating layer, and the pattern of the cloth in the coating layer appears on the surface through the transparent plastic. The pattern can be applied to the cloth by, for example, printing or weaving the cloth so that the woven fibers form the pattern, so that it is possible to employ a pattern that is difficult to express by painting. Moreover, since the transparent plastic that fills the gaps between the fibers of the fabric forms the surface,
There is no unevenness on the surface, and even if the surface is a curved surface, the cloth bends following this surface, so that wrinkles do not occur.

A fiber-reinforced plastic molded article according to another invention is the fiber-reinforced plastic molded article according to the invention described above, wherein an underlayer made of colored plastic is provided between the coating layer and the base material. Things. ADVANTAGE OF THE INVENTION According to this invention, the base layer can prevent the pattern of the base material formed of the fiber from permeating the coating layer and appearing on the surface. Further, the hue of the cloth pattern changes according to the color of the plastic forming the underlayer.

A fiber-reinforced plastic molded product according to another invention is the fiber-reinforced plastic molded product according to the invention described above, wherein the whole is formed in a bathtub shape, and the pattern of the cloth is a grain extending in one direction. The cloth is provided on each of the surfaces forming the surface of the bathtub. ADVANTAGE OF THE INVENTION According to this invention, the bathtub made of fiber reinforced plastic in which the grain pattern was drawn on the whole surface can be formed.

In the method for producing a fiber-reinforced plastic molded product according to the present invention, a patterned cloth is placed on a molding die, and a transparent plastic is spread over the cloth, cured and then cured. The base material made of fiber reinforced plastic is formed on the above layer.

According to the present invention, since the patterned cloth can be bent and slightly expanded and contracted, a transparent plastic is applied and spread to form a shape following the surface of the mold, and the plastic is cured. By doing so, it is formed in that shape. As described above, since the base material is formed after the transparent plastic is cured, the unevenness formed by the reinforcing fibers in the base material does not appear on the surface of the molded product. Since the pattern can be drawn on the cloth by, for example, printing or weaving the cloth so that the woven fibers form the pattern, it is possible to adopt a pattern that is difficult to express by painting.

[0011] A method of manufacturing a fiber-reinforced plastic molded product according to another aspect of the present invention is the manufacturing method according to the above-described aspect, wherein after the layer of the plastic having the cloth is cured and before the base material is formed, This is for forming an underlayer made of colored plastic. According to the present invention, the radius of curvature of a portion of the base material corresponding to the corner of the forming die is increased by the thickness of the base layer.

[0012] According to another aspect of the present invention, there is provided a method of manufacturing a fiber-reinforced plastic molded product, which comprises the steps of applying the transparent plastic to a cloth and curing it twice in the manufacturing method according to the above-described invention. This is to make the viscosity of the plastic in the first coating step lower than in the second coating step.

According to the present invention, since the plastic having a relatively low viscosity comes into contact with the cloth, the cloth is not forcibly pulled when the transparent plastic is spread on the cloth, and wrinkles do not occur.

According to another aspect of the present invention, there is provided a method for manufacturing a fiber-reinforced plastic molded article, wherein the viscosity of the plastic applied first to the cloth is set to a viscosity at which the cloth can be impregnated. . According to the present invention, the air that has entered between the cloth and the mold is easily released from between the fibers of the cloth, and a second transparent plastic layer is formed in a state where the air has been released. The layer of plastic can be formed thick without air. If the transparent plastic layer is thick, light passing through the gaps between the fibers of the cloth reaches the back side of the pattern, and the pattern becomes sharper. Also, a transparent plastic layer is formed on the surface side of the cloth.

According to another aspect of the present invention, there is provided a method of manufacturing a fiber-reinforced plastic molded product, which comprises using a mold for a bathtub and a cloth having a grain pattern extending in one direction. Then, the cloth is adhered to each of the surfaces to be the surface of the bathtub with a transparent plastic, and the ends of two adjacent cloths are overlapped so that the grain directions are substantially parallel.

According to the present invention, a cloth with a grain pattern can be provided on the entire surface of a bathtub forming die in a state where the grain is continuous at a portion where the cloths are connected to each other.

[0017]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS A molded article made of fiber reinforced plastic and a method of manufacturing the same according to the present invention will be described below with reference to FIGS.
This will be described in detail. In this embodiment, an embodiment in which the present invention is applied to a bathtub for a unit bath will be described. 1A and 1B show a fiber-reinforced plastic molded product according to the present invention. FIG. 1A is a plan view, and FIG. 1B is a sectional view taken along line II in FIG. 2 is a perspective view showing a bathtub, FIG. 3 is a cross-sectional view showing an enlarged part of a fiber-reinforced plastic molded product according to the present invention, and FIG. 4 is a production of a fiber-reinforced plastic molded product according to the present invention. It is an exploded perspective view for explaining a method.

In these figures, reference numeral 1 denotes a bathtub for a unit bath according to this embodiment. This bathtub 1
As shown in FIG. 2, is made of a fiber reinforced plastic (hereinafter simply referred to as FRP) having a grain pattern 2 over the entire surface thereof. And a flange 4 extending laterally from the opening edge of the opening. The grain pattern 2 has a grain direction extending in one direction, and the longitudinal direction of the surface forming the surface of the bathtub 1 is parallel to the grain direction. The direction of the grain is indicated by an arrow in FIG. Note that the four corners of the flange 4 are oblique so that the grain of the part that forms the long side and the short side of the rectangular bathtub 1 in plan view, that is, the grain extending in the direction orthogonal to each other, is connected. ing.

FIG. 3 shows a cross section of the bathtub 1 made of FRP. FIG. 3 is drawn such that the upper side is the surface of the bathtub 1. The bathtub 1 is formed with the cross-sectional structure of FIG. 3 over the entire area. In FIG. 3, reference numeral 5 denotes this FRP
1 shows a base material of a bathtub 1, and the base material 5 is formed by impregnating one or more layers of glass fibers with a plastic (unsaturated polyester resin), and is formed of a known F material.
RP. Reference numeral 6 denotes a base layer formed on the base material 5, and the base layer 6 is formed of a white-colored plastic (gel coat made of an unsaturated polyester resin).

Reference numeral 7 denotes a gel coat layer made of a transparent plastic (unsaturated polyester resin), and reference numeral 8 denotes a coating layer formed by impregnating a cloth 9 with a transparent plastic (a gel coat made of unsaturated polyester resin). The gel coat layer 7 is formed to be thicker than the coating layer 8. The transparent plastics used for the gel coat layer 7 and the coating layer 8 are made of the same material and mixed with a powdered antibacterial agent.

The cloth 9 is not dissolved by the styrene-based solvent used for the transparent plastic, and has high flexibility and can be easily adapted to a molding die described later. In the form, it is formed by weaving polyester fibers. The grain pattern 2 is printed on the surface of the cloth 9 by a screen printing method. In the case where a pattern other than a wood grain pattern is drawn, it can be attached by weaving the cloth 9 so that the woven fibers form the pattern, in addition to the screen printing method.

Next, a method of manufacturing the bathtub 1 will be described with reference to FIG. In FIG. 4, what is indicated by reference numeral 10 is a bathtub 1.
This is a stainless steel mold used to manufacture the steel. The cloth 9 is adhered to each of the surfaces forming the surface of the mold 10 (the surface of the bathtub 1) to form the bathtub 1. In this embodiment, the surface of the mold 10 is divided into 19 portions, and a cloth 9 is adhered to each of the 19 portions with a transparent plastic. Nineteen cloths 9 are indicated by reference numerals 9A to 9M in FIG.

To manufacture the bathtub 1, first, the cloths 9 A to 9
M is cut so that it has substantially the same shape as the nineteen surfaces and the grain direction is the direction shown by the arrow in FIG. Then, a scribe line is drawn on the surface of the molding die 10 to indicate the sticking position of the cloths 9A to 9M, and a release agent is applied to the entire surface of the surface. Next, the cloth 9A is placed on the mold 10 such that the grain pattern 2 is on the lower side, and a transparent plastic (gel coat made of an unsaturated polyester resin) is applied to the cloth 9A, and the cloth 9A is brushed or the like. Spread all over the area. This transparent plastic is diluted with a solvent so as to have a viscosity of impregnating the cloth 9A, and the gel coat layer 7 formed in a later step is formed.
Spread out to make it thinner. By spreading the low-viscosity plastic on the cloth 9A in this manner,
The air that has entered between the mold 10 and the cloth 9A escapes from the gap between the fibers of the cloth 9A, and the gap is filled with transparent plastic instead.

After the cloth 9A is adhered to the molding die 10 as described above, the cloths 9B to 9M are adhered in the alphabetical order of the reference symbols like the cloth 9A. This attachment is shown in FIG.
(A) The cloths 9 are overlapped in a hatched portion formed by parallel diagonal lines descending to the left. That is, the overlapping portions 9a formed on the cloths C, E, F, I, J, K, L, and M shown in FIG. More specifically, the ends of the two adjacent cloths 9 on the side adjacent to each other are overlapped so that the grain direction of the grain pattern 2 is substantially parallel.

Thus, the two cloths 9 whose grain directions are parallel to each other
The two cloths 9 whose grain directions cross each other can be adhered so that these grain patterns are continuous by overlapping the ends of the wood grain. For example, after the cloth 9G shown in FIG. 4 is adhered to the upper surface of the molding die 10 so that the four sides thereof coincide with each other, the cloth 9H is adhered such that its edge is continuous with the edge of the cloth 9G. Then, cloth 9I whose grain direction is orthogonal to cloth 9H
Are attached so that the grain lines of both ends in the longitudinal direction of the grain (both ends in the vertical direction in FIG. 1) coincide with the grain lines of the edge of the cloth 9H. That is, by moving the cloth 9I in the left-right direction in FIG. 1, the grain of the cloth 9I is connected to the grain of the cloth 9H. The overlapping portion 9a described above is provided so that a gap (a portion having no grain) is not formed between the cloth 9G and the cloth 9I even when the cloth 9I is moved in this manner.

After all the cloths 9A to 9M have been attached, the molding die 10 is inserted into a heating furnace (not shown) to cure the transparent plastic. By curing the transparent plastic impregnated in the cloth 9 in this manner, a coating layer 8 indicated by reference numeral 8 in FIG. 3 is formed. Next, a gel coat layer 7 made of a transparent plastic (unsaturated polyester resin) is formed on the coating layer 8.
The transparent plastic used for forming the gel coat layer 7 is prepared by mixing a solvent so that the viscosity is higher than that of the plastic forming the coating layer 8, and applying the solvent to the upper surface of the coating layer 8 on the molding die 10 such as a brush. Spreads all over this surface. At this time, the thickness of the gel coat layer 7 is set to be larger than that of the coating layer 8.

Thereafter, the mold 10 is inserted again into the heating furnace, and the plastic of the gel coat layer 7 is cured. After the gel coat layer 7 is formed in this manner, a white plastic (gel coat made of an unsaturated polyester resin) forming the base layer 6 is spread over the entire upper surface of the gel coat layer 7. This base layer 6 is also cured using a heating furnace in the same manner as the above-described layers.

After the underlayer 6 is cured, the base material 5 is
Formed on the upper surface of the substrate. At this time, the base layer 6 is adhered to the base layer 6 with a base material plastic (unsaturated polyester resin) impregnated with the layered glass fiber and cured using a heating furnace. After the base material plastic is cured and the molding die 10 is removed from the heating furnace, the molding die 10 comprises
By releasing the RP molded product (bath 1), the manufacturing process of the bath 1 is completed.

Therefore, in the bathtub 1, the coating layer 8 formed by impregnating the transparent cloth into the patterned cloth 9 is provided on the surface of the fiber-reinforced plastic base material 5, so that the surface of the base material 5 The grain pattern 2 of the cloth 9 in the coating layer 8 appears on the surface through the transparent plastic. This grain pattern 2 is a cloth 9
For example, since it can be attached by printing, it is possible to employ a pattern that is difficult to express by painting. Moreover, since the transparent plastic filling the gaps between the fibers of the cloth 9 forms the surface, there is no unevenness on the surface, and even if the surface is curved, the cloth 9 follows the surface. Since it bends, it does not wrinkle.

When a base layer 6 made of colored plastic is provided between the coating layer 8 and the base material 5 as in the bathtub 1 shown in this embodiment, the pattern of the base material formed by fibers Can be prevented by the underlayer 6 from passing through the coating layer 8 and appearing on the surface. Further, since the hue of the pattern of the cloth 9 changes according to the color of the plastic forming the base layer 6, the wood grain pattern 2 becomes brighter by making it white as shown in this embodiment.

As a method for manufacturing the bathtub 1, a cloth 9 with a grain pattern is placed on a molding die 10, and a transparent plastic is spread over the cloth 9 and cured. Since the method of forming the base material 5 made of fiber reinforced plastic on the (coating layer 8) is adopted, the bathtub 1 can be formed in the shape of the mold 10. This is because the cloth 9 can freely bend and slightly expand and contract, so that it is shaped to follow the surface of the mold 10 by spreading the transparent plastic.
Since the base material 5 is formed after the transparent plastic is cured, the unevenness formed by the reinforcing fibers in the base material 5 does not appear on the surface of the bathtub 1.

By forming the base layer 6 after the coating layer 8 having the cloth 9 is cured and before forming the base material 5, the radius of curvature of a portion of the base material 5 corresponding to the corner of the molding die 10 is formed. Increases by the thickness of the underlayer 6.
Therefore, the operation of forming the base material 5 so as to cover the corners can be easily performed.

Further, the process from spreading and curing the transparent plastic on the cloth 9 to curing is carried out twice, and the viscosity of the plastic in the first application process (the process of forming the coating layer 8) is measured in the second time. Coating process (gel coat layer 7
Is formed, the relatively low-viscosity plastic comes into contact with the cloth 9, so that when the transparent plastic is spread on the cloth 9, the cloth 9 is not forcibly pulled, and wrinkles are not generated. Will not occur.

In this embodiment, the viscosity of the transparent plastic spread on the cloth 9 in the first coating step is determined by the cloth 9
So that air that has entered between the cloth 9 and the mold 10 can easily escape from between the fibers of the cloth 9,
Since the second transparent plastic layer is formed in a state where the air is evacuated, the transparent plastic layer can be formed thick without any air. When the transparent plastic layer is thick, the light passing through the gaps between the fibers of the cloth 9 reaches the back side of the grain pattern 2, and the grain pattern 2 becomes clear. Further, since a transparent plastic layer is also formed on the surface side of the cloth 9, the bathtub 1 having a glossy surface can be manufactured.

In addition, in manufacturing the bathtub 1, in order to overlap two cloths 9 adjacent to each other, the ends of the two adjacent cloths are overlapped so that the grain direction is parallel. Therefore, the grain becomes continuous at a portion where the cloths 9 are connected to each other. For this reason, the bathtub 1 made of fiber reinforced plastic which imitates a wooden bathtub can be manufactured.

In this embodiment, the example in which the bathtub 1 is formed has been described. However, the present invention can be applied to any fiber-reinforced plastic molded product.
Further, the pattern applied to the cloth 9 is not limited to the wood grain pattern 2 and can be appropriately changed regardless of whether or not it is difficult to express by painting.

[0037]

As described above, according to the present invention, the surface of the fiber reinforced plastic base material is covered with the coating layer, and the pattern of the cloth in the coating layer appears on the surface through the transparent plastic. . Since the pattern can be drawn on the cloth by, for example, printing or weaving the cloth so that the pattern is formed, a pattern that is difficult to express by painting can be employed. Moreover, since the transparent plastic that fills the gaps between the fibers of the fabric forms the surface, there is no unevenness on the surface, and even if the surface is curved, the fabric bends following this surface. No wrinkles occur.

Therefore, it is possible to provide a fiber-reinforced plastic molded product that can apply a pattern that is difficult to express by painting so that the surface becomes smooth.

According to another aspect of the present invention in which the base layer is provided between the coating layer and the base material, the base layer prevents the pattern of the base material formed by the fibers from appearing on the surface through the coating layer. This makes the fabric pattern appearing on the surface vivid. Moreover, since the hue of the pattern changes according to the color of the plastic forming the base layer, it is possible to manufacture a molded product having a different hue even with one type of cloth having a pattern.

According to another invention in which the cloth pattern is a grain,
By providing a cloth having a pattern of wood grain extending in one direction on all surfaces of the bathtub, a fiber-reinforced plastic bathtub that imitates a wooden bathtub can be provided.

According to the method of manufacturing a fiber-reinforced plastic molded article according to the present invention, the patterned cloth can be freely bent and slightly expanded and contracted. Is formed in a shape following the surface of the plastic, and the plastic is cured to form the shape. As described above, since the base material is formed after the transparent plastic is cured, the unevenness formed by the reinforcing fibers in the base material does not appear on the surface of the molded product. In addition, since the pattern can be drawn on the cloth by, for example, printing or weaving the cloth so that the woven fibers form the pattern, it is possible to employ a pattern that is difficult to express by painting.

Therefore, it is possible to manufacture a fiber-reinforced plastic molded product that can apply a pattern that is difficult to express by painting so that the surface becomes smooth.

According to the method of manufacturing a fiber-reinforced plastic molded article according to another invention, in which the underlayer is formed after the plastic layer having the cloth is cured and before the base material is formed, Since the radius of curvature of the portion corresponding to the corner of the mold becomes larger by the thickness of the base layer, the operation of forming the base material so as to cover the corner can be easily performed. Therefore, a molded product having many corners can be easily manufactured.

According to the method for manufacturing a fiber-reinforced plastic molded product according to another invention in which the viscosity of the first plastic is reduced by performing the coating step of the transparent plastic twice, the plastic having a relatively low viscosity is applied to the cloth. From touching,
When the transparent plastic is spread over the cloth, the cloth is not forcibly pulled and no wrinkles are generated. Therefore, it is possible to manufacture a fiber-reinforced plastic molded product having a smooth surface.

According to a method of manufacturing a fiber-reinforced plastic molded product according to another invention, wherein the viscosity of the plastic spread first on the cloth is set to a viscosity that allows the cloth to be impregnated.
The air that has entered between 0 and 0 easily escapes from between the fibers of the cloth, and a second layer of transparent plastic is formed when the air is released. It can be formed thick. If the transparent plastic layer is thick, light passing through the gaps between the fibers of the cloth reaches the back side of the pattern, and the pattern becomes sharper. Also, a transparent plastic layer is formed on the surface side of the cloth.

Accordingly, it is possible to manufacture a fiber-reinforced plastic molded product having a glossy surface and a clear pattern.

According to the method for producing a fiber-reinforced plastic molded product according to another invention using a bathtub forming die and a wood-grained cloth, the bathtub is formed in a state where the wood grain is continuous at the part where the cloths are connected. A cloth with a grain pattern can be provided on the entire surface of the mold. Therefore, a bathtub made of fiber reinforced plastic imitating a wooden bathtub can be manufactured.

[Brief description of the drawings]

FIG. 1 is a diagram showing a fiber-reinforced plastic molded product according to the present invention.

FIG. 2 is a perspective view showing a bathtub.

FIG. 3 is an enlarged sectional view showing a part of a fiber-reinforced plastic molded product according to the present invention.

FIG. 4 is an exploded perspective view for explaining a method for producing a fiber-reinforced plastic molded product according to the present invention.

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 1 ... bathtub, 2 ... wood grain pattern, 5 ... base material, 6 ... foundation layer, 7 ...
Gel coat layer, 8 ... coating layer, 9, 9A-9M ...
cloth.

──────────────────────────────────────────────────の Continued on the front page (51) Int.Cl. ⁶ Identification code FI B29K 105: 08 B29C 67/14 U

Claims (8)

[Claims] 1. A molded article made of fiber reinforced plastic, wherein a coating layer obtained by impregnating a transparent cloth with a patterned cloth is provided on the surface of a base material made of fiber reinforced plastic. 2. The fiber-reinforced plastic molded article according to claim 1, wherein an underlayer made of a colored plastic is provided between the coating layer and the base material. . 3. The molded article made of fiber reinforced plastic according to claim 1 or 2, wherein the whole is formed in the shape of a bathtub, and the pattern of the cloth is a grain extending in one direction,
A molded article made of fiber-reinforced plastic, wherein a cloth is provided on each of the surfaces forming the surface of the bathtub. 4. A patterned cloth is placed on a mold, a transparent plastic is spread over the cloth, and the plastic is cured. After that, a base material made of a fiber-reinforced plastic is placed on the plastic layer. A method for producing a molded article made of fiber-reinforced plastic, characterized by being formed. 5. The method for producing a fiber-reinforced plastic molded product according to claim 4, wherein the base layer made of a colored plastic is formed after the plastic layer having the cloth is cured and before the base material is formed. Forming a fiber-reinforced plastic molded article. 6. The method for producing a fiber-reinforced plastic molded product according to claim 4 or 5, wherein a step of spreading the transparent plastic on the cloth and curing the cloth is performed twice, and the first is performed. A method for producing a molded article made of fiber-reinforced plastic, characterized in that the viscosity of a transparent plastic to be used is made lower than the second time. 7. The method for producing a fiber-reinforced plastic molded product according to claim 6, wherein the viscosity of the plastic applied first to the cloth is set to a viscosity at which the cloth can be impregnated. Manufacturing method of mold products. 8. The method for producing a fiber-reinforced plastic molded product according to claim 4, wherein a molding die for a bathtub is used and a cloth is one-way. In the step of placing the cloth on a mold, one cloth is adhered to each of the flat surfaces forming the surface of the bathtub with a transparent plastic, and the cloth is attached to the two adjacent planes. A method of manufacturing a molded article made of fiber-reinforced plastic, characterized in that end portions of mutually adjacent sides of a piece of cloth are overlapped so that the extending direction of the grain is substantially parallel.