JPH106405A - Fiber reinforced plastic molded object and its production - Google Patents

Abstract

PROBLEM TO BE SOLVED: To obtain a molded object suitably used as a floor material of a bathroom and capable of increasing the height of patterns of a fiber reinforced plastic molded object having protruding pattern parts on its surface and having no possibility generating a flaw such as a crack. SOLUTION: A plastic molded object has a plane part 1 and protruding pattern parts 2 protruded from the plane surface on its surface and is constituted by forming the plane part 1 by laminating a gel coat layer 4 on a fiber reinforced plastic layer 3 and forming the protruding pattern parts 2 by successively laminating a resin layer 5 and the gel coat layer 4 on the fiber reinforced plastic layer 3. When the resin layer 5 is formed, a resin containing no air bubbles is used.

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 convex pattern on its surface, which is preferably used for a floor material of a bathroom, and more particularly, to increase the height of the pattern. The present invention relates to a fiber-reinforced plastic molded product and a method for producing the same.

[0002]

2. Description of the Related Art Conventionally, waterproof pans used for bathroom floor materials and the like are molded using fiber reinforced plastic (hereinafter abbreviated as FRP), and a hand lay-up method is usually used as a molding method. . FIG. 4 shows a method of manufacturing a waterproof pan for a bathroom using a conventional hand lay-up method in the order of steps. First, as shown in FIG.
And a mold 23 having a concave pattern portion 22 are prepared. Next, as shown in FIG. 4B, a resin containing no reinforcing fibers is applied to the surface of the mold 23 to form a gel coat layer 24. Next, in a state where the gel coat layer 24 is gelled,
As shown in FIG. 4C, FRP is applied on the gel coat layer 24.
The layer 25 is laminated. In FIG. 4, x indicates reinforcing fibers, and o indicates air bubbles. The FRP layer 25 has a reinforcing fiber mat disposed on the gel coat layer 24,
It is formed by impregnating the resin with the resin and then simultaneously spraying the resin and the reinforcing fibers thereon. Subsequently, as shown in FIG.
5. Remove the air bubbles in 5. Then, although not shown, a reinforcing material or the like is laminated on the FRP layer 25 as necessary, and then the gel coat layer 24 and the FRP layer 25 are cured and released.

As shown in FIG. 6, the waterproof pan for a bathroom thus manufactured has a flat surface portion 31 and a convex pattern portion 32, and the convex pattern portion 32 is non-slip. Function as The surface is made of a gel coat layer 24, and the lower layer is made of an FRP layer 25.

However, in the above-mentioned conventional manufacturing method, the FR formed in the concave pattern portion 22 of the molding die 23 at the time of molding is formed.
The defoaming step of removing bubbles in the P layer 25 using the roller 26 was difficult, and bubbles were likely to remain in the resin. In particular, when trying to increase the height H of the convex pattern portion 32 of the bathroom waterproof pan, as shown in FIG.
Since the depth 2 is deep, the roller 26 does not enter the vicinity of the bottom of the concave pattern portion 22 in the defoaming step, and there is a disadvantage that bubbles in the FRP layer 25 in the concave pattern portion 22 cannot be sufficiently removed.

[0005] When the resin is cured in a state where air bubbles remain in the FRP layer 25, the obtained waterproof pan for bathroom becomes
As shown in FIG. 5, the FRP layer 25 inside the convex pattern portion 32
Bubbles 33 are in the middle or near the boundary between the FRP layer 25 and the gel coat layer 24. As described above, if there is a relatively large bubble having a diameter of about 1 mm inside the convex pattern portion 32, the gel coat layer 24 is likely to crack while the bathroom waterproof pan is being used. FRP layer 25
There is a problem that not only does the appearance become impaired, but also the waterproofness deteriorates. For this reason, conventionally,
Only the waterproof pan for the bathroom in which the height of the convex pattern portion 32 was less than 0.5 mm could be manufactured, and there was dissatisfaction in the point of the non-slip function.

[0006]

SUMMARY OF THE INVENTION Accordingly, an object of the present invention is to increase the height of a pattern portion of a fiber-reinforced plastic molded article having a convex pattern portion on a surface, which is preferably used for a floor material of a bathroom or the like. An object of the present invention is to provide a molded article which can be formed and has no possibility of causing defects such as cracks.

[0007]

According to a first aspect of the present invention, to solve the above-mentioned problem, the surface has a flat portion and a convex pattern portion protruding from the flat portion, and the flat portion is fiber-reinforced. A gel coat layer is laminated on a plastic layer,
A fiber-reinforced plastic molded product wherein the convex pattern portion is formed by sequentially laminating a resin layer and a gel coat layer on a fiber-reinforced plastic layer. The invention according to claim 2 is a step of forming a gel coat layer on a mold having a plane portion and a concave pattern portion, and filling the gel coat layer in the concave pattern portion with a resin material containing no air bubbles to form a resin layer. Forming, a step of forming a fiber reinforced plastic layer on the gel coat layer of the plane portion and the resin layer of the concave pattern portion, and a step of removing bubbles in the fiber reinforced plastic layer. This is a method for producing a fiber-reinforced plastic molded product.

[0008]

DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, embodiments will be described in order to make the present invention easier to understand. Such an example is
It shows one embodiment of the present invention and does not limit the present invention. It can be arbitrarily changed within the scope of the present invention.
FIG. 1 is a sectional view showing an example of a bathroom waterproof pan as an embodiment of the FRP molded body of the present invention. In FIG. 1, ×
Schematically shows a reinforcing fiber. The surface of the waterproof pan for bathroom of the present embodiment includes a flat portion 1 and a convex pattern portion 2 protruding from the flat portion 1. The flat portion 1 has a gel coat layer 4 laminated on the FRP layer 3, and the convex pattern portion 2 has a resin layer 5 laminated on the FRP layer 3, and the gel coat layer 4 is laminated thereon. Has become.

The height H from the upper surface of the flat portion 1 to the upper surface of the convex portion 2 is preferably set to about 0.5 to 5 mm. If the height H of the convex pattern portion 2 is lower than this, the anti-slipping function in the bathroom waterproof pan is not sufficiently obtained, and if it is higher than this, the feeling when walking on the barefoot with the above becomes poor. The planar shape of the convex pattern portion 2 is not particularly limited, and may be circular or elliptical, a leaf shape as shown in FIG. 2A, a star shape as shown in FIG. 2B, or (c).
The shape may be an appropriate shape such as the shape of a character as shown in FIG. The upper surface 2a of the convex pattern portion 2 is desirably flat, but the pattern can also be drawn with a shallow depression having a depth of 1 mm or less. The side surface 2b of the convex pattern portion 2 may have an angle θ between the upper surface of the flat portion 1 and the side surface 2b of the convex pattern portion 2 of more than 90 degrees, but preferably has a convex pattern with respect to the flat portion 1. The side surface 2b of the portion 2 is formed so as to rise vertically.

The gel coat layer 4 is formed continuously so as to cover the surfaces of the flat portion 1 and the convex pattern portion 2. The resin material of the gel coat layer 4 has a hard property after curing,
Those which are not brittle and have excellent water resistance and chemical resistance are preferred. The resin layer 5 is formed so as to fill the inside of the convex pattern portion 2. As a material of the resin layer 5, a thermosetting resin having a relatively low viscosity before curing is preferable. The FRP layer 3
The lower layer of the gel coat layer 4 on the surface 1 and the convex pattern 2
And is formed of a composite material obtained by combining a plastic and a reinforcing fiber. F
Glass fibers or the like can be used as the reinforcing fibers used in the RP layer 3. The thickness of the FRP layer 3 is appropriately set according to the use of the product and the like. If necessary, FR
An appropriate reinforcing material (not shown) may be laminated below the P layer 3.

The waterproof pan for a bathroom having such a configuration is manufactured, for example, as follows. FIG. 3 shows an embodiment of a method for producing a fiber-reinforced plastic molded article of the present invention in the order of steps. In FIG. 3, × indicates a reinforcing fiber, and ○
Respectively schematically shows bubbles. First, FIG.
As shown in FIG. 1, a molding die 13 having a plane portion 11 and a concave pattern portion 12 is prepared, and a resin material 4a to be the gel coat layer 4 is applied on the molding die 13.

Next, as shown in FIG.
Is filled with a resin material 5a to be the resin layer 5. At this time, the resin material 5a flows on the mold 13 on which the resin material 4a of the gel coat layer 4 is applied, and fills the concave pattern portion 12. Further, it is necessary to prevent air bubbles from being contained in the resin material 5a in the concave pattern portion 12, and for that purpose, for example, the resin material 5a of the resin layer 5 is required.
A having a relatively low viscosity may be used as a.

Subsequently, before the resin material 5a of the resin layer 5 is not cured, the FRP layer 3 is laminated as shown in FIG. The FRP layer 3 is formed, for example, on the resin material 4 a of the gel coat layer 4 applied to the surface of the molding die 13 and on the resin material 5 a of the resin layer 5 filled in the concave pattern portion 12 of the molding die 13. After arranging a reinforcing fiber mat and impregnating the resin with the mat, the resin and the reinforcing fiber can be simultaneously sprayed on the mat. Thereafter, as shown in FIG.
To remove bubbles in the FRP layer 3. Then, although not shown, a reinforcing material or the like is laminated on the FRP layer 3 as necessary, and then the gel coat layer 4, the resin layer 5, and the FRP layer 3 are cured by heating, and the mold is released.

According to the manufacturing method of this embodiment, since the resin material 5a containing no air bubbles is filled in the concave pattern portion 12 of the molding die 13, the generation of air bubbles in the concave pattern portion 12 is prevented. . Further, the resin material 5 of the resin layer 5 is provided in the concave pattern portion 12.
Since the upper surface of the molding die 13 is in a planar state in the state where the a is filled, the FRP layer 3 is formed thereon and pressed by the roller 14 so that the defoaming of the FRP layer 3 can be easily performed. , And can be advanced. Also, the concave pattern portion 1
Even when the depth 2 becomes deeper, bubbles in the concave pattern portion 12 and the FRP layer 3 can be eliminated in the same manner. Further, the plan shape of the convex pattern portion of the bathroom prevention pan is, for example, as shown in FIG.
In the case of a shape having an acute angle or a thin linear portion as shown in (b) or (c), a conventional concave pattern portion 22 of a molding die 23 is used.
The FRP layer 25 is also formed inside, and the FR
In the method of defoaming the P layer 25, the defoaming roller did not enter near the bottom of the fine concave pattern portion of the molding die, so that defoaming was incomplete and many defects were found, but according to the manufacturing method of this embodiment, ,
Even if the planar shape of the concave pattern portion 22 is complicated, generation of bubbles in the concave pattern portion 22 can be prevented by filling and molding the resin material 5a containing no air bubbles.

Thus, the waterproof pan for bathroom manufactured by the manufacturing method of the present embodiment has a flat surface portion 1 and a convex pattern portion 2 as shown in FIG. There are no air bubbles and there is no risk of defects such as cracks. Also,
Even when the height H of the convex pattern 2 is 0.5 mm or more, a product having no air bubbles in the convex pattern 2 can be obtained. The antislip function of the waterproof pan can be improved. Furthermore, even if the planar shape of the convex pattern portion 2 is a complicated shape having an acute angle, a thin linear portion, or the like, a product having no air bubbles in the convex pattern portion 2 can be obtained. Can be diversified, and a product rich in design can be obtained.

[0016]

【Example】

(Example 1) A waterproof pan for a bathroom was manufactured according to the process shown in FIG. First, the surface has a flat portion 11 and a concave pattern portion 12.
A molding die 13 was prepared. The planar shape of the concave pattern portion 12 of the molding die 13 is a leaf shape, and the depth is 2 mm.
And Next, a resin material 4a to be the gel coat layer 4 was applied to the upper surface of the molding die 13 by spraying.

Then, after the resin material 4a of the gel coat layer 4 is gelled, the resin material 5a of the resin layer 5 is poured into the concave pattern portion 12 of the molding die 13, and is filled into the concave pattern portion 12 while being spread uniformly. After that, the excess resin material 5a on the plane portion 11 of the mold 13 was removed. There were almost no bubbles in the resin material 5a filled in the concave pattern portion 12, and even if there was, the diameter was very small. Subsequently, before the resin material 5a of the resin layer 5 is hardened, a reinforcing fiber mat is disposed on the upper surface of the molding die 13, and the resin is impregnated with the mat, and the resin and the reinforcing fiber are simultaneously sprayed thereon. FR
P layer 3 was formed.

In the above embodiment, a waterproof pan for bathroom was taken as an example of a molded article using fiber reinforced plastic. However, the present invention is not limited to this, and fiber reinforced plastic having a convex pattern portion on the surface is preferred. It is applicable to a molded article using plastic.

[0019]

As described above, the fiber-reinforced plastic molded article according to the first aspect of the present invention has a surface formed of a flat portion and a convex pattern projecting from the flat portion, wherein the flat portion is formed of fibers. A gel coat layer is laminated on a reinforced plastic layer, and the convex pattern portion is formed by sequentially laminating a resin layer and a gel coat layer on a fiber reinforced plastic layer. Therefore, the defoaming operation can be separately performed on the resin layer constituting the inside of the convex pattern portion and the lower fiber-reinforced plastic layer, and high defoaming can be easily achieved. Therefore, it is possible to prevent air bubbles from remaining near the surface of the molded body after molding, and to prevent defects such as cracks on the surface of the molded body. Also,
Even if the height of the convex pattern is increased, the defoaming operation is performed on the resin layer constituting the inside of the convex pattern and the fiber reinforced plastic layer thereunder to easily achieve advanced defoaming. This can prevent defects such as cracks caused by bubbles near the surface of the molded product. Furthermore, even if the planar shape of the convex pattern portion is a complicated shape having an acute angle or a thin linear portion, etc., defoaming in the convex pattern portion can be easily and highly achieved. Can be diversified, and a molded article having a rich design can be obtained.

According to a second aspect of the present invention, there is provided a method for producing a fiber-reinforced plastic molded body, comprising: forming a gel coat layer on a mold having a flat portion and a concave pattern portion; and forming air bubbles on the gel coat layer in the concave pattern portion. Forming a resin layer by filling a resin material containing no, a step of forming a fiber-reinforced plastic layer on the gel coat layer of the flat portion and the resin layer of the concave pattern portion, The method has a step of removing air bubbles therein. Therefore, by forming a resin layer by filling a resin material containing no air bubbles into the concave pattern portion of the mold, it is possible to prevent the generation of air bubbles in the concave pattern portion. By filling the concave pattern portion with a resin material to be a resin layer, the upper surface of the mold can be made flat, so that the FRP layer formed thereon can be easily and highly degassed. be able to. Also, even if the concave pattern portion of the mold is deep, the concave pattern portion and F
Since bubbles in the RP layer can be eliminated, defects such as cracks caused by bubbles near the surface of the molded body can be prevented. Further, even if the planar shape of the concave pattern portion of the molding die is complicated, it is possible to prevent the generation of bubbles in the concave pattern portion by filling the resin material containing no bubbles here and forming the resin layer. Since it is possible, the design of the concave pattern portion can be diversified, and a molded article having a good design can be obtained.

[Brief description of the drawings]

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

FIG. 2 is a plan view showing an example of a planar shape of a convex pattern portion of the fiber-reinforced plastic molded product of the present invention.

FIG. 3 is a cross-sectional view showing an example of a method for producing a fiber-reinforced plastic molded product of the present invention in the order of steps.

FIG. 4 is a cross-sectional view showing an example of a conventional method for producing a fiber-reinforced plastic molded body in the order of steps.

FIG. 5 is a cross-sectional view showing an example of a fiber-reinforced plastic molded body according to a conventional manufacturing method.

FIG. 6 is a cross-sectional view showing a defoaming step in an example of a conventional method for producing a fiber-reinforced plastic molded product.

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 1 ... Flat part, 2 ... convex pattern part, 3 ... fiber reinforced plastic, 4 ... gel coat layer, 4a ... resin material (gel coat layer) 5 ... resin layer, 5a ... resin material (resin layer), 11 ... flat part, 12: concave pattern portion, 13: molding die.

Claims (2)

[Claims] 1. A surface comprising a flat portion and a convex pattern protruding from the flat portion, wherein the flat portion is formed by laminating a gel coat layer on a fiber reinforced plastic layer. A fiber-reinforced plastic molded product comprising a resin layer and a gel coat layer sequentially laminated on a fiber-reinforced plastic layer. 2. A step of forming a gel coat layer on a mold having a flat portion and a concave pattern portion, and a step of forming a resin layer by filling a resin material containing no air bubbles on the gel coat layer in the concave pattern portion. And a step of forming a fiber-reinforced plastic layer on the gel coat layer on the plane portion and the resin layer on the concave pattern portion, and a step of removing bubbles in the fiber-reinforced plastic layer. A method for manufacturing reinforced plastic moldings.