JPS604013A - Preparation of frp/foamed resin composite molded substance - Google Patents

Abstract

PURPOSE:To restrain deformation in the direction vertical to the compression direction of a core material and to enable the thickness of the injection mold part coated with FRP to be increased by providing cut parts to the core part on the parting line surface of an injection mold at least over its semi-spherical surface. CONSTITUTION:The inlet 6 of hardening liquid resin is provided by the injection mold 1 in the direction almost rectangular to the compression stress direction applied to the core material 2 and on the parting line surface. The core material 2 is provided with cut parts 5 at least on the semi-spherical surface, preferably all over the whole spherical surface on the portion facing the parting line surface of the injection mold 1. In this manner, since cut parts 5 are provided at least on the semi-sphere, preferably all over the spherical surface, when the core material 2 is compressed by the mold 1, the core material become hardly be deformed vertically by the adsorption of compression stress. Therefore the thickness of the FRP coated layer area on the parting line surface is made equal to that of other places and strength can be improved.

Description

Detailed Description of the Invention [Field of Industrial Application] The present invention uses a foam made of a resin such as polystyrene, polyethylene, phenol resin, urea resin, polyurekne, or polypropylene as a core material, or the surface of this foam is made of a styrene-free material. A core material covered with a permeable resin film and a glass fiber reinforced resin (
The present invention relates to a method for manufacturing a composite molded body made of FRP (hereinafter referred to as FRP).

The manufacturing method of the present invention is suitable for manufacturing surfing boards, cold storage containers, floating equipment, fishing tanks, mail containers, medicine tanks, and show window cases.

[Prior art]

Core material made of resin foam such as polyethylene or polystyrene,
Alternatively, a core material with a styrene-impermeable resin film provided on the surface of the foam is used, a glass fiber mat is placed on the core material, and an injection mold is used to mold the core material to 1.2 to 2.5 K111.
0. The glass fiber cloak and the foam are pressurized with the mold clamping pressure of II, and while the foam and mat are being compressed, the injection mold is filled with metal through an inlet installed in the direction of the compressive stress applied to the core material. A curable liquid unsaturated polyester resin composition or epoxy resin composition is injected under pressure into the cavity in the mold, and then the composition is cured to provide a resin reinforced with glass fibers on the surface of the foam. FRP/foamed resin compound, 7, o, ni, 6, 6□, i,. ,ゎ 154-550
No. 88, No. 54-155265, No. 55-8261
No. 2, No. 57-182426, patent application No. 57-1637
No. 73).

This FRP/foam composite molded product has excellent strength, chemical resistance, heat insulation, and light weight, so it is used for cold containers, floating devices, chemical tanks, show window cases, boats, etc.

This injection molding method is superior in dimensional accuracy, productivity, appearance, and quality uniformity compared to the method of manufacturing FRP/R foam composites using the full composite nodry amplifier method or the spray amplifier method.
In addition, it has the advantage that it can be used as a product in which reinforcing bodies such as wood or metal, screws, nuts, etc. are inserted between the FRP and the foam.

If the shape of this FRP/foamed composite is a plate-shaped body,
The strength of the FRP skin is generally high and there is no problem, but it can be used in rugby pole shapes, spherical shapes, etc. like floating devices, surfing boards, etc.
In the case of a crime, as shown in Fig. 1, the foam core material 2 whose core material (indicated by a phantom line) is compressed by the injection mold 1 is greatly deformed, and the core material 2 is under compressive stress. Since it is easy to deform in the direction perpendicular to the direction of
The distance t0 becomes narrower to Ll when the mold is clamped, and therefore F'
The thickness of the FRP coating layer in this portion (P) of the RP/foamed resin composite molded product is thinner than in other portions, which has the disadvantage that the strength is weak.

Further, in the above method, the liquid resin injection port 6 is 3B 1
As shown in the figure, since the core material 2 was provided in the direction of compression, the liquid resin injected into the mold cavity 4 of the mold 1
It is necessary to provide a runner (not shown) in the mold in order to uniformly reach the inside of the mold, making the design of the mold difficult.

[Purpose of the invention]

The first object of the present invention is to cut not only plate-shaped objects but also rugby ball-shaped, spherical, and spherical objects by cutting at least half the circumference of the core material located on the parting line surface of the injection mold. By providing a portion, the core material is prevented from deforming in the direction perpendicular to the compression direction, and the thickness of the FRP coating layer portion located at the parting line 1jji of the injection mold is increased, and the thickness of the other portions is increased. The aim is to improve the wall thickness to a thickness equivalent to or even thicker, and to strengthen the parts where the strength would otherwise be weakened.

The second purpose is to create a p-type mold by providing an inlet for the curable liquid resin approximately perpendicular to the direction of compressive stress applied to the core material of the injection mold, and on the parting line surface of the injection mold. To enable liquid resin to be injected and injected into the mold cavity uniformly and thoroughly without providing a runner.

The third purpose is to prevent the glass fiber reinforcement from protruding beyond the parting line surface of the mold by tying the entire circumference of the glass fiber reinforcement at the cut-out part of the core material with glass fiber yarn. The goal is to prevent

The fourth purpose is to create a composite molded product using glass fiber yarn.
It is important to strongly reinforce it.

The fifth purpose is to quickly spread the injected curable liquid resin throughout the mold cavity by using glass fiber yarns through the gaps in the yarns.

[Method of invention]

■The first method of the present invention is the first method. In order to achieve the second object, in the method for manufacturing an FRP/foamed resin composite molded article, the second. As shown in FIG. 3, the inlet 6 for the curable liquid resin is inserted into the injection mold 1 at approximately right angles to the direction of the compressive stress applied to the core material 2 of the two-inch mold 1. The n1 core material 2 provided on the cutting line surface is a parting lie method of the injection mold 1.

(2) The second method of the present invention is a method in which the entire circumference of the fiber reinforcing material 8 at the cut portion 5 is bound with fiber yarns 7 in order to achieve the fourth and fifth objects in the first method.

The core material 2 in the present invention may be a foam (density 0.01-0.3 f〆ml) of a resin such as polystyrene, polyethylene, polystyrene-polyethylene copolymer a, phenol resin, urea resin, or polyurethane. This surface is coated with unsaturated polyester resin Gelco~1□, Yuia1=
Y, A2,2 Kaju 86, □Vinegar It is also possible to use a material coated with latex such as vinyl monate.

Curable liquid resins include unsaturated polyester resin, epoxy resin, and vinyl resin (epoxy acrylate resin).
, polyurethane resin, etc. are used.

Examples of fiber reinforcing materials include glass fiber, carbon fiber, polyester fiber, and nylon fiber. Among these, glass fiber is inexpensive. Such glass fiber reinforcement can be in the form of mats, strands, or rovings.

Furthermore, examples of the fiber yarn include those obtained by knitting strands of the above-mentioned fiber reinforcing material into a string shape. Generally, yarns having a diameter of 1 to 5 holes are used. Since the yarn has voids, the injected resin can quickly reach the mold cavity through the voids.

〔Example〕

Part 2 regarding an embodiment of the present invention. This will be explained with reference to FIG.

[Example of manufacturing foam]

Expandable particles of styrene (105 parts)/polyethylene (100 parts) copolymer 1 ELENBOLL'' (trade name, manufactured by Yuka Verdice ■) were pre-foamed with steam at 104° C. to obtain pre-foamed beads.

The beads were introduced into a gold cavity with a steam introduction slit, and steam at 114°C was introduced, and then cooled to a density of 0.05 f/(yl), 300 mm vertically,
A rugby ball-shaped foam with a width of 750+wm and a height of 300m was obtained.

A V-shaped notch 5 @ (opening width L == 15 TWL+,
A cutting angle of 60 degrees) was provided around the entire circumference, and a film was applied to the entire curve of the foam using a cold-curing unsaturated polyester resin composition 1 Yukajiku 38-06'' (trade name) manufactured by Nippon Upicar ■. It was applied to a thickness of 40 microns and cured at room temperature to form a styrene-impermeable resin film on the surface of the foam.

Foam having the above styrene-impermeable resin film (core material 2)
A continuous strand mat made of Asahi Fiberglass ■ made of lath fiber 1 Glasslon M8600-4sb # (trade name), weighing 450 sh, is layered in double layers on the entire surface of the core moon 2. Glass fiber yarns 7 having a diameter of about 3+w were wrapped twice around the entire circumference of the glass fiber reinforcing material 8 at the cut portion 5 and tied. A pair of molds 1a and lb moving in the vertical direction adjusted to a mold temperature of 40°C
The injection mold 1 was inserted into the cavity 4 coated with a release agent. (Figure 2) Next, the mold 1 was closed and the glass fiber mat (glass fiber reinforcement) 8 and the core material 2 were compressed with a mold clamping pressure of 1-8y4/clll (the core material 2 was compressed with the mold clamping pressure). The wall thickness is approximately 21
). In the process of closing the mold 1 with the mold clamping pressure, a room temperature curable unsaturated polyester resin composition (
A curable liquid resin) is injected into the cavity 4 of the injection mold 1 through the nozzle 9 inserted into the injection port 6 provided on the parting line surface of the mold 1 at an injection pressure of 2-5'/crA.
It was cured for 30 minutes at 0°C.

Room temperature curable unsaturated polyester resin composition> Phthalic anhydride/fumaric acid/propylene glycol unsaturated alkyd ω part (B), styrene 40 parts ((), methyl ethyl ketone peroxide 0.9 parts (
r3.6% cobalt naphthenate solution 0.3 parts (FJ,
After curing 3 parts of the ff color pigment, the mold was opened to obtain an FRP/foamed resin composite (floating device). The dimensions of this product were approximately 3,021 mm in length, approximately 752 mm in width, and approximately 302 mg in height, and the average thickness of the FRP layer was approximately 2 mm. Further, the thickness of the FRPP located on the parting line surface was about 6fi. Furthermore, FRP
The glass fiber content in the layer was tit 30.

In the composite molded article (floating tool) of Jin, there was no swelling or shrinkage of the foam, and the adhesion between the foam and the FRP layer was strong enough to cause no practical problems.

The FRP surface of this composite had excellent gloss, and no lifting of glass fibers was observed.

〔Effect of the invention〕

As is clear from the above description, according to the first method of the present invention, (1) a part of the core material 2 located on the parting line surface of the injection mold l is coated over at least half the circumference, preferably over the entire circumference; Since the notch 5 is provided, the core material 2 is inserted into the mold 1.
When the core material 2 is compressed, the core material 2 deforms in a direction perpendicular to the direction of the compressive stress due to the action of absorbing the compressive stress by the cut portion 5, and the FR located on the parting line surface deforms.
The thickness of the P coating layer portion is equal to that of other portions, and the strength can be improved. ■Also, since the injection port 6 for the curable liquid resin is provided approximately perpendicular to the direction of compressive stress applied to the core material 2 by the injection mold 1, and on the parting line surface of the mold 1, Even without providing a runner, the injected liquid resin can be evenly distributed throughout the cavity 4 of the mold 1, making it possible to obtain products with excellent uniformity of quality, and eliminating the need for a runner. design becomes easier.

If the second method of the present invention is used, the following effects will be obtained in addition to the effects (1) and (2) obtained when the first method is employed.

That is, (1) the entire circumference of the glass fiber reinforcement material 8 in the cut portion 5 of the core material was bound with the glass fiber yarn 7;
The glass fiber reinforcing material does not protrude outside the mold 1 from the perphic line surface of the mold 1. ■The composite molded body can be further reinforced by the glass fiber yarn 7. ■
By using the glass fiber yarn 7, the injected curable liquid resin can be quickly distributed throughout the cavity 4 of the mold l through the yarn 7, thereby increasing productivity. .

[Brief explanation of the drawing]

Figure 1 is a cross-sectional view of molding using the conventional method.
FIG. 2 is a cross-sectional view showing the state during molding using the method of the present invention, and FIG. 3 is a cross-sectional view showing the state at the end of molding. l・・・・・・Injection mold, 2・・・・・・・・・
Core material, 3... Edge of mold l, 4...
・・・・・・Cavity of mold 1, 5・・・・・・・・・
Cut portion, 6... Injection of curable liquid resin 1'', 7...Glass fiber yarn, 8
......Glass fiber mat (glass fiber reinforcement material), 9...Nozzle. (1,1

Claims (5)

[Claims] (1) A fiber reinforcing material is placed on a core material made of a resin foam having a density of 0.01 to 0.3 f/d or a core material whose surface is coated with a styrene-impermeable resin film, The fiber reinforcing material and core material are compressed using a pair of injection molds, and while both are being compressed, a hardening liquid is poured into the cavity in the mold from the injection port provided in the injection mold. In the method of manufacturing an FRP/foamed resin composite molded article by injecting a resin and then curing the curable liquid resin, the injection port for the curable liquid resin is inserted into the resin foam core material by an injection mold. The resin foam core material is provided at a parting line surface of the injection mold substantially perpendicular to the direction of compressive stress applied to the parting line surface of the injection mold. A method for manufacturing an FRP/foamable resin composite molded article, characterized in that a cut portion is provided over at least half of the circumference. (2) Density is 0.01~0.3'/,! A fiber reinforcing material is placed on a core material made of a resin foam or a core material whose surface is coated with a styrene-impermeable resin film, and a pair of injection molds are used to insert the fiber reinforcing material and the core material. The core material is compressed, and while both are being compressed, a curable liquid resin is injected into the cavity in the υ mold through an injection port provided in the injection mold, and then the curable liquid resin is cured. In the method for manufacturing an FRP/foamed resin composite molded article, the inlet for the curable liquid resin is arranged substantially perpendicularly to the direction of compressive stress applied to the resin foam core material by the injection mold, and The resin foam core material is provided at the parting line m1 of the injection mold, and a cut portion is provided over at least half the circumference of the resin foam core material in a portion thereof located on the parting line surface of the injection mold. Also, a method for manufacturing an FRP/foamed resin composite molded article, characterized in that the entire circumference of the fiber reinforcing material at the cut portion of the core material is bound with fiber yarn. (3) The method for manufacturing an FRP/foamed resin composite molded article according to claim 1, wherein the cut portion of the core material is provided over the entire circumference of the core material. (4) F according to claim 1 or 2, wherein the fiber reinforcing material is a glass fiber mat.
Method for manufacturing RP/foamed resin composite molded product. (5) The method for producing an FRP/foamed resin composite molded article according to claim 2, wherein the fiber yarn is a glass fiber yarn.