JPH1060123A - Surface material for molding of fiber-reinforced plastic, molding using the same, and process for preparing the molding - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a surface material for molding of a fiber-reinforced plastic which can stably provide a molding free from offshade trouble and is very advantageous in cost. SOLUTION: A nonwoven fabric or a woven fabric made of a thermoplastic resin fiber or an inorg. material fiber colored with a colorant is used as a surface material 1. A decorative layer 2 may be provided on the surface material 1. The surface material 1 is put on top of SMC or BMC 3 so that SMC or BMC 3 comes into contact with the nonwoven fabric. The laminate is heated and pressed within a mold to cure SMC or BMC 3 and, at the same time, to integrate SMC or BMC 3 with the surface material. Improved covering power of the surface material 1 can provide a stable product. Further, by virtue of high covering power of the surface material 1, the toning of underlying FRP is unnecessary, making it possible to use a low grade, inexpensive FRP material.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a sheet molding compound which is an intermediate material of a fiber reinforced plastic (FRP) before hot pressing.
Compound = SMC: A material adjusted so that it can be immediately charged into a mold when making an FRP molded body by hot press molding. It contains glass fiber and thermosetting resin such as unsaturated polyester resin, additives, etc. It is a molding material mixed into a sheet. ) Or Bulk Molding Compound (BMC: S
The same material as MC but in bulk (lumpy, three-dimensional). More specifically, the present invention relates to a surface material for FRP molding used for simultaneous decoration of SMC or BMC molding, a molded body using the same, and a method of manufacturing the molded body.

[0002]

Conventionally, since a molded article formed only by SMC is inferior in design, it has been practiced to overlap and integrate appropriate surface materials at the time of molding. One of the surface materials is disclosed in Japanese Patent Application Laid-Open No. S51-20951.
Gazette, Japanese Patent Application Laid-Open No. 53-146767,
There is a nonwoven fabric or a woven fabric having a desired decorative layer provided on the surface by printing or the like as disclosed in Japanese Patent No. 32767, JP-A-4-341809 and the like. However, when such a surface material is laminated and integrated with the FRP, the resin component of the FRP penetrates and fills the voids, so that the nonwoven fabric or woven fabric becomes transparent. Therefore, the color of the underlying FRP material affects the surface and
There is a problem that color unevenness due to color blur (color tone error) or color deterioration of the RP or poor dispersion of the pigment in the FRP is likely to occur, and these so-called color difference troubles are different for each FRP production lot. . A material with less color blur, color deterioration and color unevenness may be used, but the cost is increased. In addition, FRP toning is required for each desired color. In this respect, the cost is increased, and further, labor and time for toning are added.

Attempts have also been made to form a concealing layer on the entire surface of a non-woven fabric or woven fabric by solid printing with an ink containing a highly concealing pigment such as titanium dioxide. With such a configuration, the concealing property is improved, but the non-woven fabric or woven fabric has a non-uniform distribution of fiber aggregation density, length, thickness, etc.,
So-called "formation unevenness" is inevitable, and therefore, a color tone corresponding to the formation unevenness also occurs in the solid color tone (density and the like) of the entire surface. Further, since the printing ink layer has a thickness on the order of several μm, it is difficult to perfect the concealing property.

[0004] The present invention has been made in view of the above problems, and an object of the present invention is to obtain a fiber having a stable molded body free from color difference troubles and having a great cost advantage. An object of the present invention is to provide a reinforced plastic molding surface material, and also provide a molded article using the same and a method for producing the molded article.

[0005]

In order to achieve the above object, a surface material for molding a fiber-reinforced plastic according to the present invention comprises a nonwoven fabric or woven fabric made of a thermoplastic resin fiber or an inorganic fiber colored with a coloring pigment. It is characterized by consisting of. For example, the fiber may be impregnated with a resin mixed with a coloring pigment. And it is preferable to perform a decoration process on the surface of the nonwoven fabric or the woven fabric. Further, a surface protection layer may be provided.

[0006] Then, in the molded body using the surface material for molding fiber-reinforced plastic, the surface material is overlapped so that the nonwoven fabric surface or the woven fabric surface is in contact with SMC or BMC, and heated and pressed in a mold. It is manufactured by hardening SMC or BMC and integrating them at the same time.

[0007] The surface material of the present invention having the above-described structure can uniformly distribute the pigment throughout the thickness direction of the nonwoven fabric or woven fabric by mixing the coloring pigment into the nonwoven fabric or woven fabric itself. It became. For this reason, the integrated value of the amount of pigment added in the thickness direction is greatly increased as compared with the case where the colored ink is solidly printed on the surface of the nonwoven fabric or woven fabric, and the concealment of the sheet can be greatly improved. As a result, the F
It is possible to obtain a molded product that is hardly affected by the color of RP.
In addition, since the pigment is dispersed in the nonwoven fabric or woven fabric, there is no variation in the amount of ink absorbed or transferred due to formation unevenness as in the case of surface printing of colored ink, and coloring unevenness is further reduced.

[0008]

Next, an embodiment of the present invention will be described.

As the nonwoven fabric or woven fabric, so-called "paper" using cellulose fibers can be used, but it is insufficient from the viewpoints of moldability into three-dimensional shapes, dimensional stability and strength.
Therefore, when thermoforming property at the time of FRP molding is required, a thermoplastic resin whose temperature at the time of FRP molding is located between its Vicat softening temperature and its melting point (or melting temperature) is used as a material. Specifically, fibers such as acryl, polyester, polyamide, vinylon, nylon, acrylonitrile, and olefin resin are selected and used so as to be compatible with the molding temperature of FRP. Also, a combination of acrylic and polyester, polyester and olefin-based resin, and the like can be mixed. Alternatively, when dimensional stability at the time of FRP molding and the strength of the molded product are required, an inorganic fiber having a melting point equal to or higher than the temperature at the time of FRP molding is used as a material. Specifically, fibers such as glass, carbon, asbestos, and potassium titanate are used. These nonwovens and woven fabrics have a basis weight of 25
の も の 500 g / m ² is used.

As the coloring pigment, among general organic or inorganic pigments, those having a desired color tone and sufficient hiding properties are selected. For example, titanium dioxide for white, antimony trioxide, zinc white, etc., carbon black for black, cyanine black, etc., yellow for yellow, titanium yellow,
Pigment Yellow L, Isoindolinone, etc., if red, red petal, cadmium red, lithol fast scarlet G, quinacridone, etc., if blue, cobalt blue,
Ultramarine, phthalocyanine blue and the like can be used. These pigments can be mixed with a non-woven fabric to form a paper or impregnated into fibers, or fibers spun from a resin containing these pigments in advance can be used, but more preferably mixed with a binder (resin) of the non-woven fabric. Impregnated into a non-woven fabric. Examples of the impregnated resin include thermosetting resins such as DAP (diallyl phthalate), melamine resin, phenol resin, and epoxy resin, acrylic resins, thermoplastic resins such as vinyl acetate, vinyl chloride-vinyl acetate copolymer, vinylon, and polyvinyl alcohol, and natural resins. Rubbers such as rubber, butadiene rubber, and styrene-butadiene rubber are used. The content of the coloring pigment is about 5 to 30% by weight.

When decorative treatment is applied to the surface of a nonwoven fabric or a woven fabric, a wood grain pattern such as cedar, zelkova, teak, a stone grain pattern such as marble or granite, a stripe pattern, a polka dot pattern or the like is mainly printed. A picture such as a pattern is formed. As the printing means, a method such as direct printing on nonwoven fabric or woven fabric by gravure printing, silk screen printing, or the like, transfer printing using a transfer sheet, or lamination of preprinted resin sheets is used. As a decoration process other than the printing of a pattern, a metal thin film of aluminum, chromium, or the like can be partially formed by a known method.

When a surface protective layer is provided, a transparent or translucent plastic film may be laminated or a protective film may be formed by coating. Painting is also possible. The layer thickness is about 1 to 100 μm. This surface protective layer prevents the wear of the picture and the deterioration of the surface. Examples of the plastic (resin) to be used include an acrylic resin, a polyester resin, a urethane resin, a fluorine resin, and an epoxy resin. In particular, when weather resistance is required, it is preferable to use an acrylic resin such as polymethyl methacrylate, or a fluororesin such as polyvinylidene fluoride, polyvinyl fluoride, and ethylene / tetrafluoroethylene copolymer. If necessary, benzotriazole,
About 0.1 to 5% by weight of an ultraviolet absorber such as fine particle cerium oxide and a light stabilizer such as a hindered amine radical scavenger are added.

As SMC, glass fiber, carbon fiber,
An unsaturated polyester resin or a vinyl ester resin obtained by kneading fibers such as potassium titanate fiber, a catalyst, a filler, a release agent, and the like can be used. In addition, thermosetting resins such as diallyl phthalate, acryl, melamine, and epoxy can be used in some cases. These resins are usually used in a prepolymer state. Fibers such as glass usually contain 10 to 70% by weight. Powders such as calcium carbonate, barium sulfate, and aluminum hydroxide are used as the filler. As a release agent, zinc stearate or the like is used. In addition, if necessary, a reactive diluent (crosslinking agent and diluent) such as a styrene monomer and a tributylstyrene monomer, a crosslinking agent such as an isocyanate and an amine, benzoyl peroxide, methyl ethyl ketone peroxide, and tbutyl perbenzo. A curing catalyst such as eight or an organic sulfonate, a thermoplastic resin such as polymethyl methacrylate, or the like is added. SMC is molded in an uncured or semi-cured state. Also,
As a molding material for FRP, besides SMC, BMC etc.
Other forms may be used.

The molding conditions of the SMC set the temperature and time at which the thermosetting resin can be cured. This varies depending on the resin used, but typically the temperature is 60 to 180 ° C., the pressure is 30 to 200 kg / cm ² , and the molding time is about 1 to 30 minutes. The mold used for molding is made of metal or ceramic. Various shapes can be considered for the shape of the molded body depending on the application, and typically, a plane, a cylinder, a polygon,
There are various types of bathtubs, dishes, trays, and outer plates of ships and vehicles.

[0015]

【Example】

(Example) First, a surface material 1 provided with a decorative layer 2 as shown in FIG. 1 is prepared. Specifically, a polyester resin binder prepared by mixing 30% by weight of titanium dioxide is produced,
This binder is made of a polyester resin and has a basis weight of 50.
The impregnated nonwoven fabric of g / m ² was used for the surface material 1. On the surface of the impregnated nonwoven fabric, a marble stone pattern is gravure-printed with an ink obtained by adding a color pigment to a mixture of an acrylic resin and a vinyl chloride-vinyl acetate copolymer as a binder. Layer 2 was formed.

Next, as shown in FIG. 2, a color pigment composed of titanium dioxide, an unsaturated polyester resin, glass short fibers, styrene monomer, SMC3 composed of benzoyl peroxide and zinc stearate were prepared. The SMC 3 and the nonwoven fabric surface of the surface material 1 are overlapped so that they are in contact with each other.
The heating and pressurizing were performed for 5 minutes at 50 ° C. and 100 kgf / cm ² to cure the SMC3 and integrate them. Thus, a molded body for a bathroom wall having a marble pattern was obtained. The obtained molded article has a high concealing property of the nonwoven fabric, and can sufficiently cover the color unevenness due to the color blur of the base FRP and the poor dispersion of the pigment, and the unevenness of the color tone due to the uneven formation of the nonwoven fabric is also observed. Did not. Further, no color change of the molded product due to the difference between the production lots was observed.

(Comparative Example) The same polyester resin non-woven fabric as that of the example was used, and a non-impregnated non-woven fabric was used as a surface material. And it superimposed on the same SMC as an Example, and was molded on the same conditions. The obtained molded product had color defects due to color blur of FRP and poor dispersion of pigment, and color unevenness corresponding to the formation unevenness of the nonwoven fabric was also conspicuous. Further, the color change due to the difference between the production lots resulted in the color change of the molded product as it was, which caused a trouble.

[0018]

As described above, if the molding is performed using the surface material for molding fiber-reinforced plastic of the present invention, there is no need to adjust the color of the underlying FRP and a low-grade, inexpensive FR is used.
The P material can be used, and the amount of the FRP pigment can be reduced, thereby obtaining a cost advantage. In the past, there were many color differences due to color blur, color deterioration or color unevenness of the FRP material. However, the surface material for molding a fiber-reinforced plastic of the present invention provides a stable product by improving the concealing property. Now you can get it. Further, as compared with the solid printing of the concealing ink, the unevenness of the color tone due to the uneven formation was small, and the concealing property was higher.

[Brief description of the drawings]

FIG. 1 is a sectional view showing an example of a surface material for molding a fiber-reinforced plastic of the present invention.

FIG. 2 is a sectional view showing a molded body using the surface material of FIG.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Surface material 2 Decorative layer 3 SMC

──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. ⁶ Identification code Agency reference number FI Technical display location B32B 27/20 9349-4F B32B 31/20 31/20 B29C 67/14 G

Claims (6)

[Claims] 1. A fiber-reinforced plastic molding surface material comprising a nonwoven fabric or a woven fabric made of thermoplastic resin fibers or inorganic fibers colored with a coloring pigment. 2. The surface material for molding a fiber-reinforced plastic according to claim 1, wherein a resin mixed with a coloring pigment is impregnated in the fiber. 3. The surface material for molding a fiber-reinforced plastic according to claim 1, wherein a decoration treatment is applied to a surface of the nonwoven fabric or the woven fabric. 4. The surface material for molding a fiber-reinforced plastic according to claim 1, wherein a surface protective layer is provided. 5. A molded article characterized in that the surface material for molding a fiber-reinforced plastic according to claim 1 is integrated on the surface. 6. A method for producing a molded article using the fiber-reinforced plastic molding surface material according to claim 1, wherein the nonwoven fabric surface or the woven fabric surface is formed of a sheet molding compound or a bulk molding compound. A method for producing a molded article, comprising superimposing the sheets so as to be in contact with each other, heating and pressurizing in a mold, curing the sheet molding compound or the bulk molding compound, and simultaneously integrating them.