JPH11245213A - Press template for manufacture of building board and manufacture thereof - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a press template for a building board which is of a desired shape and free from bubbles and a method for manufacturing the press template for a building board. SOLUTION: A first swirl mat 2a shaped like a mat by stacking continuous glass fibers in a swirl fashion, a chopped strand mat 2b shaped like a mat by stacking glass fibers cut to the specified length and a second swirl mat 2c shaped like a mat by stacking the continuous glass fibers in the swirl fashion are laid up from a mold face 11B side to form a three-tier layer. This three-tier layer mat is inserted into a cavity in a mold 4 which comprises a top force 5 and a bottom force 6 and has a positive shaped mold face 11b corresponding to the surface shape. Further, a resin is injected into the cavity to be cured.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a press plate for manufacturing a building board, which is used for forming an uneven pattern on the building board when manufacturing the building board, and a hand lay-up method or a resin injection molding. The present invention relates to a method for producing a press template for a building board by a method.

[0002]

BACKGROUND OF THE INVENTION At present, a fiber-reinforced inorganic plate is often used as a building exterior plate. When manufacturing these inorganic plates, in order to enhance the design and enhance the commercial value, usually press-press a template having an uneven pattern on the surface of the uncured molded plate formed by molding the raw material mixture, the inorganic plate An uneven pattern is formed on the surface.

Heretofore, a metal plate such as an iron plate has been used as the press-formed plate having the concavo-convex pattern. However, recently, since the weight is large, the production is not easy, and the cost is increased, a glass fiber reinforced plate has recently been used. Those made of thermosetting resin (FRP) are generally used. Such an FRP press mold plate is advantageous in that it is lightweight and can be manufactured by a simple process of injecting a resin into a matrix and curing it.

[0004]

2. Description of the Related Art
In order to manufacture a press mold plate made of P by the hand lay-up method, a glass fiber is cut into a predetermined length on a mold surface of a matrix having an uneven pattern corresponding to the surface shape of a building board, and a stacking mat. A laid chopped strand mat is laid, a thermosetting resin mixed with a curing agent is applied thereon, and the mat is impregnated. The laying of the chopped strand mat and the application and impregnation of the thermosetting resin are repeated several times to form an FRP layer having a predetermined thickness and to cure the FRP layer.

[0005] Repeating the laying of the mat and the application and impregnation of the resin as described above is performed by laying a plurality of chopped strand mats or by impregnating the resin into a thick chopped strand mat at one time. This is because the resin is difficult to spread to the mold surface side and corners of the mat, and defects are generated in the obtained press mold plate. However, such repetitive steps are extremely complicated and workability is poor, resulting in an increase in manufacturing cost. I was

On the other hand, in order to manufacture the above-mentioned FRP press mold plate by a resin injection molding method, a cavity of a mold having an upper mold having a resin injection port and a lower mold having an irregular pattern on the mold surface is usually provided. Insert a chopped strand mat in advance, and from the resin inlet,
A thermosetting resin mixed with a curing agent is injected and cured.

However, when only a chopped strand mat is used as the reinforcing fiber of the FRP, the penetration of the resin is very slow, and the resin is difficult to completely spread over the entire cavity, and the bubbles generated in the resin are formed between the glass fibers. Therefore, there is a problem that the obtained press template does not have a desired shape or that bubbles are generated in the obtained press template.

Accordingly, it is an object of the present invention to provide a press plate for a building board having a desired shape and free of air bubbles, and a method by which such a press board for a building board can be manufactured. is there.

[0009]

In order to solve the above-mentioned problems, the present invention is directed to a press template (3) for manufacturing a building board having a negative mold surface corresponding to the surface shape of the building board.
On the mold surface side, a swirl layer in which continuous glass fibers are stacked spirally, on the opposite side of the mold surface, a glass fiber reinforced resin having a chopped strand layer in which glass fibers are cut to a predetermined length and stacked, or A first swirl layer (31) in which continuous glass fibers are spirally stacked, a chopped strand layer (32) in which glass fibers are cut to a predetermined length and stacked, and a second swirl layer in which continuous glass fibers are spirally stacked. And a swirl layer (33) comprising a fiber-reinforced resin having a three-layer structure.

[0010] The press mold plate (3) for manufacturing a building board is placed on the mold surface (11A) of a matrix (1A) having a positive mold surface (11A) corresponding to the surface shape of the building board. Mold surface (11
A) From the side, a two-layer structure of a swirl mat in which continuous glass fibers are spirally stacked to form a mat and a chopped strand mat in which glass fibers are cut to a predetermined length to form a stacked mat, or a continuous glass fiber. A first swirl mat (2
a), a chopped strand mat (2b) in which glass fibers are cut to a predetermined length to form a stacked mat, and a second swirl mat (2c) in which continuous glass fibers are stacked in a spiral to form a mat. The mat is laid so as to form a layer structure, and the matrix (1A) is covered with a resin (R).
(4) which is manufactured by injecting and hardening the mold, or which has an upper mold (5) and a lower mold (6) and has a positive mold surface (11B) corresponding to the surface shape of the building board.
A swirl mat formed by spirally stacking continuous glass fibers into a mat shape, and a chopped strand formed by cutting glass fibers into a predetermined length in a cavity (7) from the mold surface (11B) side. A two-layer structure of a mat, or a first swirl mat (2a) in which continuous glass fibers are spirally stacked to form a mat, and a chopped strand mat (2b) in which glass fibers are cut into a predetermined length to form a stacked mat. And a second swirl mat (2c) formed by spirally stacking continuous glass fibers into a mat, and inserting the mat into a three-layer structure.
It is manufactured by injecting and curing the resin (R) into the cavity (7).

In the latter manufacturing method, it is preferable to inject the resin (R) into the cavity (7) of the mold (4) while the mold (4) is inclined.
The upper mold (5) has a plurality of resin injection ports (51a, 51b, 51).
c) is provided, and the resin (R) is injected in order from the resin injection port (51a) set at the lower stage to the resin injection port (51c) set at the upper stage due to the inclination of the mold (4). It is preferred to do so.

[0012]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described below in detail with reference to the drawings. In the first manufacturing method (so-called hand lay-up method) of a press template for building board production according to the present invention,
As shown in FIG. 1, a positive mold corresponding to the surface shape of a building board, here, a matrix 1A having a mold surface 11A having an uneven pattern is used. The material of the matrix 1A is not particularly limited, but examples thereof include diallyl phthalate resin reinforced with fibers such as glass fiber, carbon fiber, ceramic fiber, and rock wool, unsaturated polyester resin, styrene resin, and urea. Resins, melamine resins, synthetic resins such as phenolic resins, or ceramics, gypsum, and inorganic materials such as silicates.Preferred materials include unsaturated polyester containing glass fibers or styrene-unsaturated polyester and gypsum. No.

In the present invention, after a mold release agent is applied to the mold surface 11A of the matrix 1A, the swirl mat 2 is placed on the mold surface 11A.
a, the chopped strand mat 2b, and the swirl mat 2c are laid in this order (FIG. 1). Note that a three-layer mat in which the swirl mat 2a, the chopped strand mat 2b, and the swirl mat 2c are integrally formed in advance may be used.

The swirl mat is formed by spirally stacking continuous glass fibers to form a mat, and has excellent resin impregnation. The weight of the swirl mat is 300-500
g / m ² is preferred. On the other hand, the chopped strand mat is obtained by cutting glass fiber (strand, roving) into a predetermined length to form a stacked mat, and gives a high strength to the FRP. The length of the glass fiber in the chopped strand mat is preferably 20 to 50 mm on average, and the basis weight is preferably 300 to 600 g / m ² . The weight ratio of the swirl mat 2a, the chopped strand mat 2b and the swirl mat 2c is 1:
It is preferably from 2: 1 to 1: 4: 1.

After the mats 2a, 2b, and 2c are laid as described above, the resin R is injected into the matrix 1A as shown in FIG. As the resin, a thermosetting resin such as a diallyl phthalate resin, an unsaturated polyester resin, a styrene resin, a urea resin, a melamine resin, or a phenol resin is usually used. When the resin is injected into the matrix 1A, a curing agent is added. Is done.

In the present invention, the resin is injected after all the mats 2a, 2b, 2c are laid, but the swirl mat 2
Since a and 2c are excellent in impregnating property of the resin, the resin R injected into the matrix 1A quickly permeates the upper swirl mat 2a first, and after being transferred to the chopped strand mat 2b, further lowers the swirl mat 2c. Penetrate into In this way, the resin R is applied to each of the mats 2a, 2b,
2c sufficiently spreads to all corners, and particularly reaches the uneven portion of the mold surface 11A without fail.

When the injection of the resin R is completed, the upper mold having the mold surface coated with a release agent is placed on a resin-impregnated mat and pressed slightly to cure the resin. (FIG. 3). The resin is usually cured at room temperature, but may be heated if desired. After the resin is cured, the press template 3 shown in FIG. 4 is taken out.

As a result of the resin being sufficiently distributed to each of the mats 2a, 2b and 2c, the obtained press mold plate 3 is formed into a desired shape, and a negative uneven pattern corresponding to the surface shape of the building board is surely formed. . The press mold plate 3 has a three-layer structure of a first swirl layer 31, a chopped strand layer 32, and a second swirl layer 33 on which a negative concavo-convex pattern is formed. In particular, the chopped strand layer 32 is used as a core material. By doing so, sufficient strength is maintained.

In the method of manufacturing a press template for manufacturing a building board described above, the swirl mat 2a, the chopped strand mat 2b, and the swirl mat 2c are arranged on the mold surface 11A of the matrix 1A in this order. Although 2c is laid, the present invention is not limited to this, and two mats 2a and 2b may be laid in the order of the swirl mat 2a and the chopped strand mat 2b. Also in this case, a two-layer mat in which the swirl mat 2a and the chopped strand mat 2b are integrally formed in advance may be used. The weight ratio between the swirl mat 2a and the chopped strand mat 2b is preferably from 1: 1 to 1: 3.

Even in the case of the two-layer structure of the swirl mat and the chopped strand mat as described above, the resin injected into the matrix 1A can be used as the mold surface 11 by the swirl mat.
In order to reliably reach the portion of the uneven pattern of A, a negative uneven pattern corresponding to the surface shape of the building board is surely formed on the obtained press die plate. This press die plate has a two-layer structure of a swirl layer and a chopped strand layer on which a negative uneven pattern is formed. In particular, sufficient strength is maintained by using the chopped strand layer as a backing.

Next, a second manufacturing method (so-called resin injection molding method) of a press template for building board production according to the present invention will be described. In the present manufacturing method, for example, a molding die 4 as shown in FIG. 5 is used. The molding die 4 includes an upper die 5
And a lower mold 6, and a space surrounded by the upper mold 5 and the lower mold 6 forms a cavity 7. The upper mold 5 is provided with a plurality of resin injection ports 51a, 51b, and 51c having valves 511 (in this case, a total of six), and air vent pipes 52a are provided at both ends in the longitudinal direction of the upper mold 5. , 52b are connected two each. The material of the upper mold 5 is not particularly limited, but acrylic resin, polyethylene resin,
It is preferably a transparent material such as a polypropylene resin or a polyester resin.

On the other hand, the lower mold 6 comprises a lower frame 61 and a mother die 1B incorporated in the lower frame 61, and the mold surface 11B of the mother die 1B.
Has a positive shape corresponding to the surface shape of the building board, here, an uneven pattern. The matrix 1B is made of the same material as the material of the matrix 1A used in the hand lay-up method. A mating surface 62 of the lower frame 61 with the upper die 5
A packing mounting groove is provided around the mating surface 53 of the upper die 5 with the lower frame 61, and a packing 81 is mounted in the packing mounting groove. The upper mold 5 and the lower mold 6 are fixed by fastening brackets 54 provided at four corners of the upper mold 5 and brackets 63 provided at four corners of the lower frame 61 with bolts 82. Is done.

A method for manufacturing a press plate for manufacturing a building board using the molding die 4 will be described. First, a release agent is applied to the mold surface 55 of the upper mold 5 and the mold surface 11B of the matrix 1B, and then the swirl mat 2a, the chopped strand mat 2b, and the swirl mat 2c are applied to the cavity 7 of the mold 4 from below. The mats 2a, 2b, 2c are inserted in order (FIG. 5). Note that a three-layer mat in which the swirl mat 2a, the chopped strand mat 2b, and the swirl mat 2c are integrally formed in advance may be used. The swirl mats 2a and 2c and the chopped strand mat 2b can be the same as those used in the hand lay-up method.

After each of the mats 2a, 2b, 2c is inserted into the cavity 7 of the molding die 4, the upper die 5 is overlaid on the lower die 6, and the bracket 54 of the upper die 5 and the bracket 63 of the lower frame 61 are placed.
And the upper mold 5 and the lower mold 6 are fixed.

Next, the resin is injected into the cavity 7 of the molding die 4, and it is preferable that the resin is injected while the molding die 4 is inclined. In particular, it is preferable to incline so that the longitudinal direction of the mold 4 is inclined.
Preferably it is between 10 ° and 45 °. Specifically, as shown in FIG. 6, the mold 4 may be placed on the inclined gantry 9. When the resin is injected in such a state that the mold 4 is inclined, air in the cavity 7 is easily released, and bubbles generated in the resin are easily discharged to the outside of the cavity 7. However, if the inclination angle θ is less than 10 °, these effects cannot be sufficiently obtained. If the inclination angle θ exceeds 45 °, there is a possibility that the resin injection becomes difficult or the reinforcing fibers are biased. The valves 511 of the resin injection ports 51a, 51b, 51c are opened in advance.

As the resin, the same resin as that used in the above-mentioned hand lay-up method may be used. The resin is supplied from the pump 10 to the cavity 7 of the mold 4 through a forked resin injection pipe 101 connected to the pump 10.
Inject into First, the resin injection tube 101 is connected to the resin injection ports 51a, 51a (lower stage) of the upper mold 5, and the resin injection port 51
The resin R is injected into the cavity 7 through a and 51a (FIG. 6). The resin R injected from the resin injection ports 51a, 51a is:
Along the inclination of the mold 4, the air first flows down to the lower stage of the cavity 7, and at this time, the air in the lower stage of the cavity 7 is
It is discharged out of the cavity 7 from 52a, 52a. The resin R fills the lower part of the cavity 7 to remove the air vent pipes 52a, 52a.
a, the air vent pipes 52a, 52a are
Close by 1.

After the resin R fills the lower part of the cavity 7, the resin R then goes back to the middle part of the cavity 7, and the air in the cavity 7 pushed by the resin R is discharged to the resin inlet 51b,
The air is discharged out of the cavity 7 through 51b, 51c, 51c and the air vent pipes 52b, 52b. When the resin R fills the lower half of the middle stage of the cavity 7 and reaches the resin injection ports 51b, 51b, the resin injection from the resin injection ports 51a, 51a is stopped.
The valve 511 of the resin injection port 51a, 51a is closed.

Next, the resin injection pipe 101 connected to the resin injection ports 51a, 51a is removed, and the resin injection ports 51b, 51a are removed.
b (middle), and the resin R is injected into the cavity 7 through the resin injection ports 51b, 51b (FIG. 7). Resin injection port
The resin R injected from 51b, 51b goes back to the upper middle stage of the cavity 7, and the air in the cavity 7 pushed by the resin R is released from the resin injection ports 51c, 51c and the air vent pipe 52.
b and 52b are discharged out of the cavity 7. The resin R
Fills the entire middle stage of the cavity 7 with the resin injection port 51c,
When the temperature reaches 51c, the resin injection from the resin injection ports 51b, 51b is stopped, and the valve 511 of the resin injection ports 51b, 51b is closed.

Further, the resin injection pipe 101 connected to the resin injection ports 51b, 51b is removed, and the resin injection ports 51c, 51b are removed.
The resin R is injected into the cavity 7 through the resin injection ports 51c, 51c (FIG. 8). The resin R injected from the resin injection ports 51b, 51b goes back to the upper stage of the cavity 7, and at that time, the air in the upper stage of the cavity 7 is discharged out of the cavity 7 from the air vent pipes 52b, 52b.
The resin R fills the upper stage of the cavity 7 and the air vent pipe 52
b, 52b, the resin injection from the resin injection ports 51c, 51c is stopped, and the valve 51 of the resin injection ports 51b, 51b is stopped.
1 is closed, and the air vent pipes 52b, 52b are closed by clips 521.

In the present invention, the swirl mats 2a and 2c inserted into the cavity 7 of the molding die 4 have excellent resin impregnating properties.
a, 2b, and 2c are fully spread, especially the mold surface 11
It surely reaches the part of the uneven pattern of B. Also, even when bubbles are generated in the resin, the swirl mat 2
The bubbles hardly stay in a and 2c.

Particularly, in the present embodiment, since the resin is injected in a state where the molding die 4 is inclined, the air in the cavity 7 is easily evacuated, and the synergistic effect with the above-described swirl mat allows the resin to be quickly transferred to the entire cavity 7. Can be completely distributed. Further, the bubbles generated in the resin float along the inclination of the upper mold 5 without being hindered by the glass fibers, and the resin injection ports 51a, 51b, 51c and the air vent pipe are formed.
Since the air is discharged from the air outlet 52b, bubbles are effectively prevented from remaining in the resin.

After the injection of the resin is completed, the resin is cured in that state. The resin is usually cured at room temperature, but may be heated if desired. After the resin has hardened, the bolts 82 fastening the bracket 54 of the upper mold 5 and the bracket 63 of the lower frame 61 are removed, and the upper mold 5 and the lower mold 6 are divided, as shown in FIG. The press template 3 is taken out.

As a result of the resin being sufficiently distributed to each of the mats 2a, 2b and 2c, the obtained press mold plate 3 is formed into a desired shape, and a negative uneven pattern corresponding to the surface shape of the building board is surely formed. . In addition, since no bubbles remain in the resin, generation of pinholes is also prevented. This press template 3
Has a three-layer structure of a first swirl layer 31, a chopped strand layer 32, and a second swirl layer 33 on which a negative concavo-convex pattern is formed. In particular, by using the chopped strand layer 32 as a core material, Strength is maintained.

In the manufacturing method (resin injection molding method) of the press plate for building board production described above, the swirl mat 2a, the chopped strand mat 2b, and the swirl mat 2c are sequentially placed in the cavity 7 of the molding die 4 from below. The mats 2a, 2b and 2c of the swirl mats 2 are inserted from below.
a, two mats 2a and 2b may be inserted in the order of the chopped strand mat 2b. Even in this case,
Swirl mat 2a and chopped strand mat 2
A two-layer mat in which b is integrally formed in advance may be used.

The method of the present invention has been described with reference to the drawings. However, the present invention is not limited to the embodiments shown in the drawings, and various changes can be made without departing from the scope of the present invention. it can. For example, in the above-described resin injection molding method, the resin is injected in a state where the mold 4 is inclined, but the resin injection may be performed in a state where the mold 4 is horizontal.
The number of resin injection ports of the upper die 5 in the molding die 4 is not limited to six, and may be appropriately set according to the size of the die surface area, the viscosity of the resin, and the like. Further, the resin injection port may be opened and closed with a stopper, a clip, or the like instead of the valve 511.

[0036]

According to the present invention, it is possible to manufacture a press plate for a building board having a desired shape and having no air bubbles.

[Brief description of the drawings]

FIG. 1 is a manufacturing process (first stage) of a press die plate according to the present invention.
FIG.

FIG. 2 is a manufacturing process (second stage) of a press die plate according to the present invention.
FIG.

FIG. 3 is a manufacturing process (third stage) of the press die plate according to the present invention;
FIG.

FIG. 4 is a perspective view of a press template according to an example obtained by the method of the present invention.

FIG. 5 is a perspective view of a molding die (upper die and lower die) according to an example used in the present invention.

FIG. 6 is a manufacturing process (first stage) of a press die plate according to the present invention.
FIG.

FIG. 7 is a manufacturing process (second stage) of the press die plate according to the present invention.
FIG.

FIG. 8 is a manufacturing process (third stage) of the press die plate according to the present invention;
FIG.

[Description of Signs] 1A, 1B: Matrix 11A, 11B ... Mold surface 2a, 2c ... Swirl mat 2b ... Chopped strand mat 3 ... Press mold plate 31, 33 ... Swirl layer 32 ... Chopped strand layer 4 ... Mold 5 ... Upper mold 51a, 51b, 51c ... resin inlet 511 ... valve 52a, 52b ... air vent tube 521 ... clip 53 ... mating surface 54 ... bracket 55 ... mold surface 6 ... lower mold 61 ... lower frame 62 ... mating surface 63 ... bracket 7: Cavity 81: Packing 82: Bolt 9: Inclined gantry 10 ... Pumping pump 101: Resin injection tube

Claims (8)

[Claims] 1. A press template for building board production having a negative mold surface corresponding to the surface shape of the building board, wherein a swirl layer in which continuous glass fibers are spirally stacked on the mold surface side. A press template for building board production, comprising a glass fiber reinforced resin having a chopped strand layer in which glass fibers are cut to a predetermined length and stacked on the opposite side of a mold surface. 2. A press template for manufacturing a building board having a negative mold surface corresponding to the surface shape of the building board, wherein a first swirl layer in which continuous glass fibers are spirally stacked, and a glass fiber are formed in a predetermined shape. A chopped strand layer cut into lengths and stacked, and a fiber-reinforced resin having a three-layer structure of a second swirl layer formed by spirally stacking continuous glass fibers. Board. 3. A swirl mat in which continuous glass fibers are spirally stacked on the mold surface of a matrix having a positive mold surface corresponding to the surface shape of a building board from the mold surface side to form a mat. And laying the mat so as to have a two-layer structure of a chopped strand mat formed by cutting glass fibers into a predetermined length to form a stacked mat, and injecting a resin into the matrix to cure. Manufacturing method of press template for building board production. 4. A first swirl mat or glass fiber in which continuous glass fibers are spirally stacked on a mold surface having a positive mold surface corresponding to the surface shape of a building board to form a mat shape. Are cut into predetermined lengths to form a three-layered structure of a chopped strand mat, which is a stacked mat, and a second swirl mat, which is a continuous swirl mat formed by spirally stacking continuous glass fibers. ,
A method for producing a press plate for building board production, comprising injecting a resin into the matrix and curing the resin. 5. A mat formed by spirally stacking continuous glass fibers from the mold surface side in a cavity of a mold having an upper mold and a lower mold and having a positive mold surface corresponding to the surface shape of a building board. Inserting the swirl mat and the glass fiber into a two-layer structure of a chopped strand mat formed by cutting the glass fiber into a predetermined length and injecting a resin into the cavity to cure it A method for manufacturing a press template for manufacturing a building board, characterized by comprising: 6. A first type in which continuous glass fibers are spirally stacked in a cavity of a molding die having an upper mold and a lower mold and having a positive mold surface corresponding to a surface shape of a building board to form a mat. A swirl mat, a chopped strand mat in which glass fibers are cut to a predetermined length to form a stacked mat, and a second swirl mat in which continuous glass fibers are spirally stacked to form a mat are formed. A method for producing a press template for building board production, comprising inserting the mat, injecting a resin into the cavity, and curing the resin. 7. The method according to claim 5, wherein a resin is injected into a cavity of the mold while the mold is inclined. 8. The upper mold is provided with a plurality of resin injection ports, and the resin is injected in order from the lower resin injection port to the upper resin injection port due to the inclination of the molding die. The method for producing a press template for producing a building board according to claim 7, wherein the method is performed.