KR20180052409A - Manufacturing method of inner and outer phenol laminate panel Used phenolic resin and unsaturated polyester resin - Google Patents

Abstract

The present invention relates to a method to manufacture a phenol laminate panel used for an electric train, a train, a door of a building, indoor and outdoor buildings, etc. According to the present invention, the method comprises: a step of coating gelcoat of a selected color on a surface of a mold on which a releasing agent (releasing wax) is coated and curing the gelcoat; a step of layering a space mat on a gelcoat layer and impregnating the space mat with an unsaturated polyester (UP) resin; a step of impregnating an upper surface of the impregnated space mat with glass fiber; a step of stacking another glass fiber on the impregnated glass fiber, wherein a half from the bottom of the stacked glass fiber is impregnated with the UP resin, the remaining half is not impregnated, and curing is performed; a step of coating a phenol resin on an upper surface of the glass fiber after a lower layer of the glass fiber whose upper part is not impregnated is cured, stacking the glass fiber on the upper surface, and performing curing for 1 to 2 hours; a step of putting a vacuum film on the upper surface of a cured glass fiber layer, sealing edges, performing evacuation, and then performing curing for 3 to 5 hours; and a step of processing the edge of an interior/exterior phenol laminate panel cured after the evacuation to complete the same. According to the present invention, provided is an effect capable of polymerizing an UP resin weak to moisture during curing and a phenol resin generating moisture during the curing to manufacture the phenol laminate panel.

Description

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing an inner and outer phenolic laminate panel using a dermal resin and a phenolic resin,

The present invention relates to a method of manufacturing a phenol laminate panel for use in an electric vehicle, a train, a door of a building, indoor and outdoor buildings, and more particularly, to a method of manufacturing a phenol laminate panel, Ester resin) and glass fiber are sequentially applied and cured. After applying the phenolic resin, the glass fiber is laminated and the panel after the curing is made. Thus, the UP resin which is vulnerable to moisture at the time of curing and the phenol resin which generates moisture at the time of curing are polymerized, The present invention relates to a method for manufacturing a phenol laminate panel for interior and exterior use using a dermal resin and a phenolic resin.

Previously, FRP-based embedded panels were used in railway, train, building doors, indoor and outdoor buildings.

However, conventionally, in order to manufacture a panel made of FRP, a panel manufacturing method using only a pulverulent resin or a panel manufacturing method using only an UP resin has been carried out.

The reason why the UP resin and the phenol resin can not be used together is that they can not be used in the same polymerization due to different physical properties.

That is, when the phenolic resin is impregnated with the glass fiber, the UP resin generates moisture when cured due to the characteristics of the phenolic resin during curing, whereas when the UP resin is cured with moisture, The resin and the phenol resin were not used together.

Prior art of this field is disclosed in Japanese Patent Application Laid-Open No. 10-2006-0017029 (published on Feb. 23, 2006), and a method of manufacturing the panel with a phenol laminate for subway (hereinafter referred to as "prior art" ,

A method for manufacturing a synthetic resin built-in panel of a train and a train,

A step of forming a mold with a shape and a shape of a built-in panel to be formed, and applying a mold-releasing wax to the surface of the mold so that the product to be molded subsequently can be well formed;

Applying a phenol laminate gel coat of a selected color to the surface of the mold having the modified wax applied thereon, and curing it at 80 to 100 캜 in a drying chamber;

A step of laminating a mat formed of a cloth and a cloth on the phenol laminate gel coat application layer;

Laminating a release film on the mat surface;

A step of laminating a breeder on the laminated release film so as to be used as an air passage in vacuum;

A step of sequentially laminating a vacuum film on the upper surface of the release film on which the bleeder is laminated and sealing it with a sealant;

A step of applying a vacuum to the encapsulated vacuum film using a valve at a pressure of 60 cmHg for 20 to 40 minutes;

Performing a vacuum so as to be completely cured in a drying chamber at a temperature of 80 ° C to 120 ° C after the vacuum for 40 to 100 minutes;

And a step of cutting and inspecting the cured inner panel after desiccation, thereby manufacturing a panel with built-in phenol laminate for a subway.

The above prior art is disclosed by the applicant of the present invention, which discloses a phenol laminate knitted panel using only a phenol resin. However, since the UP resin can not be polymerized together with the flame retardant effect due to the characteristics of the phenol resin There is a problem that durability such as strength of metal is not obtained.

There is a problem in that the UP resin and the phenol resin can not be polymerized together due to the problem that the UP resin susceptible to moisture at the time of curing and the phenol resin which generates moisture at the time of curing are polymerized to make a phenol laminate panel.

Korean Patent Publication No. 10-2006-0017029

Disclosure of the Invention The present invention has been made in view of the above problems, and it is an object of the present invention to provide a panel having improved strength and being incombustible by polymerizing UP resin and phenol resin during the production of an FRP panel in a mold having a shape to be manufactured In addition, it is possible to display various kinds of colors by using gelcoat, and to make the coloring process at the same time as molding without needing to separate powder coating after the panel is manufactured, so that the production process can be simplified, To a method for manufacturing a phenol laminate panel for interior and exterior use.

As a means for solving the above-mentioned object, the present invention provides a method of manufacturing a mold, comprising the steps of applying and curing a gel coat of a selected color on the surface of a mold having a release agent (release wax) applied thereto;

Placing a space mat on the gel coat layer and impregnating it with UP resin;

Impregnating glass fiber on a space mat impregnated with the UP resin;

Another glass fiber is laminated on the impregnated glass fiber, but the laminated glass fiber is laminated so that 1/2 of the glass fiber is impregnated with the UP resin and the other half is not impregnated;

Applying a phenol resin to the upper surface of the glass fiber after laminating the lower layer of the glass fiber without being immersed in the upper layer, laminating the glass fiber on the upper surface, and curing the laminate for 1 to 2 hours;

Placing a vacuum film on the upper surface of the cured glass fiber layer, sealing the rim, vacuuming and curing for 3 to 5 hours;

And a step of finishing the edge of the phenol laminate panel for internal and external use which is cured after the vacuum is completed.

The present invention as described above can shorten the working process by enabling the production of the required color without any additional coating process for the surface treatment in the conventional panel manufacturing method, and at the same time, it is possible to form the FRP panel by using the UP resin and the phenol resin And at the same time, it is possible to provide a phenol laminate panel for internal and external use which has a flame retardancy and is light in weight while lowering the cost of the product.

The present invention provides a phenol laminate panel capable of producing a desired color without a separate coating process, shortening the manufacturing process to reduce cost, and manufacturing a panel by polymerizing UP resin and phenol resin to improve the durability and light weight And a flame retardant panel.

1 is a view illustrating a manufacturing process according to a method of manufacturing a phenol laminate panel for internal and external use according to the present invention,
2 is a cross-sectional view of a phenol laminate panel for internal and external use according to an embodiment of the present invention,
3 is an exemplary view showing a tent product manufactured by the panel manufacturing method of the present invention.

Hereinafter, embodiments of the present invention will be described in detail.

The characteristics of the UP resin and the phenol resin in the present invention are as follows.

◎ UP resin (UP: unsaturated polyester resin) is a polymer compound belonging to thermosetting plastic. It is made of a primary resin having a molecular weight of 1,000 to 3,000 and having a polymerizable double bond. The UP resin is a vinyl monomer such as styrene To form a molded product.

In addition to fiberglass, fibers such as nylon and tetron are also used and used as engineering plastics.

This resin is commonly called fiber reinforced plastics (FRP) because it is reinforced with glass fibers. Using recently developed molding methods, FRP can be made with the same strength as steel. Therefore, fibers such as nylon and tetron are used as well as glass fiber, and they are used as engineering plastics (industrial plastics).

A representative example of making the first resin for general use is a first polyester obtained by taking the molar ratio of propylene glycol 1.1, maleic anhydride 0.5, and phthalic anhydride 0.5 and heating and condensing.

When the polymerization catalyst is mixed with the styrene at a weight of about 30%, a bridge bond is formed between the first resin and the styrene to be cured.

Usually, a mixture of styrene in the first resin is commercially available. In actual use, a skeleton is made of glass fiber, and a mixture of the polymerization resin and a polymerization catalyst is impregnated with the mixture to cure at room temperature to form a molded article. However,

As described above, the UP resin can form various panels using glass fiber. There is a weak point to fire.

◎ Phenolic resin is also called phenolic resin (phenolic resin). Phenols are usually used as phenolics, but cresols are also used. The first resin produced by the acid catalyst in the manufacturing process is referred to as novolak, and the resin produced by the basic catalyst is referred to as resol, both of which have a small molecular weight. The appearance is similar to the rosin left after removing essential oil from Songji. When hexamethylenetetramine is added to the novolac, it is pressed and heated in a mold to be hardened to form a molded article (dry method).

The resole is cured when it is directly pressurized and heated (wet method). Resol is dissolved in alcohol, impregnated with cloth, paper, board in it, dried, and rolled and heated. The laminate (laminate) is used as an insulating plate for switchboards, large switches, etc., and as an adhesive, it gives various plywoods water resistance. In addition, rubber and fiber adhesives used in tire manufacturing are especially made from phenol with resorcin

(Thermosetting) resin produced by the condensation of phenols and formaldehyde. It is similar to rosin, and the phenols used are mainly phenol. Depending on the catalyst used in the manufacturing process, novolac and resole are obtained, respectively. The former is cured by the dry method and the latter by the wet method. It is mainly used for insulating plates and adhesives, etc. [Naver Knowledge Jack and Excerpt]

In the present invention, the wet curing method and the dry method are performed in parallel to form a panel.

UP resin is not cured in the presence of water, and the ferrous resin generates moisture during curing. Therefore, the space mat and the glass fiber are impregnated with the UP resin, and the glass fiber located in the upper part is impregnated with the UP resin After the phenol resin is applied on the non-impregnated top surface, the glass fibers are laminated and cured for 1 to 2 hours.

The curing time can be set to the number of laminated glass fibers for at least 1 hour to 2 hours.

In addition, the thickness of the phenol laminated panel according to the present invention can be increased by increasing the number of glass fibers to be impregnated in the UP resin at the time of manufacturing, and thinning can be achieved by reducing the number of laminated layers.

In the present invention, the UP resin and the phenolic resin are polymerized and used when the panel is molded using the space mat and the glass fiber, so that the FRP panel can be manufactured with the same strength as the steel sheet, And the like.

Hereinafter, the manufacturing process according to the present invention will be described. First, a molding frame having an inner and outer panel shape such as a subway, a train, a train, etc. to be manufactured is formed.

The mold frame to be manufactured may be formed in various shapes according to the shape of the built-in panel.

The present invention, which is manufactured in this way, will explain an embodiment of the process for manufacturing a phenol laminate panel for use in a train, a train, a door of a building, indoor and outdoor buildings, and the like.

Step 1: Formation of mold and mold release agent application step (S1)

First, in order to form inner and outer panels such as a train, a train, a door of a building, indoor and outdoor buildings of the present invention, a basic mold is manufactured by processing a separate mold as a product to be molded.

A mold-forming mold 10 to be produced using the FRP is produced in the basic mold formed as described above.

The mold release agent (mold release wax) 20 is uniformly and uniformly applied to the entire inner surface of the molding die 10.

The releasing agent 20 applied to the inner surface of the forming die 10 is for facilitating the demolding of the outer panel of the subsequently molded phenol resin from the forming die 10.

Step 2: Applying gel coat (S2)

After the releasing agent 20 is coated on the inner surface of the mold 10 as described above, a gel coat 30 of a selected color is coated on the releasing agent layer 20 so as to smooth the surface of the product and form a desired color, Layer.

The application of the gelcoat 30 of the color selected in the present invention requires the putty work and the sending work on the surface of the phenol molded by the limit of the panel manufacturing method in the conventional interior and exterior panel, The paint surface is painted or painted on the surface of the panel, which complicates the process and increases the cost. On the other hand, the use of the gelcoat of the present invention has a noncombustible incombustibility, .

The gelcoat used in this process is prepared by using the gelcoat 30 manufactured and circulated by color, and when it is prepared and used, a gelcoat having a color by mixing a hardener and a pigment in the colorless gelcoat raw material, Can be manufactured.

The color of the selected gel coat 30 is the color formed on the outer surface of the panel to be formed later.

The gelcoat is applied in a thickness of between 0.1 and 0.5 mm.

Step 3: Gelcoat curing step (S3)

After the mold release agent 20 is coated on the inside of the mold 10, the gel coat 30 is applied in a thickness of 0.1 to 0.5 mm and dried at room temperature for 1 to 3 hours.

At this time, the curing process may be cured at room temperature for 1 hour and then cured for 10 to 20 minutes in a separately installed oven.

The drying temperature in the oven is in the range of 80 ° C to 100 ° C. That is, if it is dried after setting the temperature to 80 ° C or less, the drying takes place due to the low temperature, but the drying time is long and the productivity is low.

When the temperature is rapidly dried at a temperature of 100 ° C or more, a difference in strength may occur depending on the change in hue and the time for curing, so that the drying temperature of the gelcoat 30 is preferably 80 ° C to 100 ° C.

Step 4: Installation of space mat and UP resin impregnation step (S4)

In the second and third steps, the gel coat 30 is applied and cured, and then the space mat 40 is laminated on the gel coat layer. Then, a liquid UP resin is applied using a roller (not shown) do.

When the liquid UP resin is applied using the rollers, the space mat 40 is impregnated with the liquid UP resin and the air bubbles generated between the gel coat 30 and the space mat 40 are removed, (30) and the space mats (40) by air bubbles.

Fifth step: glass fiber impregnation step with UP resin (S5)

When the glass fiber 50 is laminated on the space mat 40 impregnated in the fourth step, the UP resin impregnated in the space mat 40 is sucked and adhesive property is generated by the UP resin.

The glass fiber 50 has a density of 300 to 600 mesh. The glass fiber is laminated on the UP resin. The glass fiber 50 is impregnated with a glass fiber sheet using a brush or a roller, .

In order to increase the thickness of the panel, a plurality of glass fibers are laminated, and then the UP resin is impregnated using a brush or a roller in the same manner as described above.

As described above, glass fibers (also referred to as a mat) are laminated and a glass fiber layer 50 is laminated on the upper surface impregnated with the UP resin, and the lower half of the glass fiber layer impregnated in the UP resin is impregnated with the UP resin And the glass fiber is dried in the upper half from the middle to the upper surface so as to be laminated.

Reference numeral 50 in the present invention refers to a glass fiber layer impregnated in a UP resin, and a glass fiber layer adhered to a phenol resin to be described later is described as 70. [

Step 6: UP resin and glass fiber curing step (S6)

In the fifth step, the glass fibers 50 are laminated, and 1/2 of the glass fibers to be laminated are cured at room temperature for 1 to 2 hours without being impregnated with the UP resin.

When curing in an oven without curing at room temperature, the curing process is carried out in an oven at a temperature of about 50 ° C to 60 ° C for about 10 to 20 minutes.

Step 7: Phenol resin application and glass fiber installation step (S7)

A phenol resin (60) is applied on the cured glass fiber (50).

The phenolic resin 60 is applied on the upper surface of the glass fiber layer not impregnated with the UP resin, and then the glass fiber 70 is laminated again.

In this case, the ratio of the glass fibers is set to 30 to 60 parts by weight based on 100 parts by weight of the total number of the glass fibers used for forming the panel to be molded in the present invention.

Therefore, 40 to 70% by weight of the glass fiber 50 impregnated in the UP resin: 30 to 60% by weight of the glass fiber 70 impregnated in the phenol resin.

Also, the glass fiber layer 50 impregnated in the UP resin is laminated to 40 to 70% by weight of the glass fibers to be laminated, while the glass fiber layer impregnated in the UP resin is impregnated in the UP resin in the upper part from the lower part, The upper half is not impregnated with the UP resin.

For example, when the thickness of the glass fiber sheet is 0.3 to 0.5 mm and four glass fibers are provided on the side of the UP resin impregnation portion, the four glass fibers are impregnated with the UP resin, and the four laminae are laminated without being impregnated with the UP resin And then cured.

When the UP resin impregnated portion is cured as described above, a phenol resin is applied on the upper side of the upper half of the dried glass fiber layer, and then the glass fiber is impregnated.

The glass fiber which is not impregnated with the UP resin is coated with a phenol resin and the glass fiber which is laminated in the weight ratio is adhered to the laminate by a phenol resin. Even if moisture is generated during the curing, The glass fiber layer which is not impregnated into the UP resin at the bottom and the glass fiber layer bonded to the phenol resin at the upper part are solidly integrated to form a panel.

Further, the stiffness of the FRP panel made of the glass fiber is controlled by adjusting the amount of the UP resin to increase or decrease its stiffness.

Step 8: Vacuum step (S8)

After the seventh step, the vacuum film 80 is brought into close contact with the uppermost portion of the glass fiber 70 adhered by the phenol resin to the edge of the forming die 10, and then the vacuum film frame is sealed (sealed) .

At this time, a non-woven fabric (not shown) is installed in a state where the outer edge of the mold frame 10 is sealed (sealed) so as to prevent air from entering.

After the nonwoven fabric is installed, a vacuum valve base is provided on the upper portion of the nonwoven fabric, and a vacuum film 80 is further provided on the upper portion of the vacuum valve 80. At this time, a portion coupled to the vacuum valve is protruded toward the upper portion of the vacuum film 80 .

After the vacuum film 80 is installed, a vacuum valve is coupled to the vacuum valve base to perform vacuum.

For the sake of simplicity, it is common practice in the industry to provide a vacuum film on a molding frame to seal a frame of a vacuum film and to form a vacuum valve base for forming an FRP panel, so that a detailed description thereof will be omitted.

Vacuum performed in the present invention is vacuumed at a pressure of 60 cmHg to 70 cmHg for 20 to 40 minutes to form a phenol laminate panel.

Since the vacuum time varies depending on the thickness of the product and the vacuum pressure does not vary greatly, it is sufficient to perform the vacuum time at a pressure of 60 cmHg to 70 cmHg.

Further, the present invention can be formed into various standards, and the height of each stacked sheet is adjusted to arbitrarily control the vacuum pressure and the time.

Step 9: Curing and demolding step (S9)

Vacuum is performed through the eighth process, and then curing is carried out at room temperature for 3 to 5 hours.

In this case, if the vacuum is not applied during curing, shrinkage may occur during the curing process, so that the shape of the surface may be deformed. Therefore, the vacuum suction must be continuously performed until the curing is completed.

As another embodiment, when curing is performed in a drying chamber, it is cured at a temperature of 80 ° C to 150 ° C for 40 to 100 minutes.

 In this case, when the thickness is large, drying is performed at 120 ° C. for 100 minutes, and when the thickness is thin, drying is performed at 80 ° C. for 40 minutes. However, the temperature and the time may be set to be different from each other depending on the thickness of the laminated mat .

If the vacuum is not applied during the curing process in the drying chamber, shrinkage may occur during curing, so that the shape of the surface may be deformed. Therefore, as in the case of normal temperature, vacuum suction must be continuously performed until complete curing.

After the fully cured panel is desiccated in the drying chamber, the laminated sealant and the vacuum film are peeled from one side of the panel.

In the present invention, since the sealant (vacuum seal), vacuum film, and the like, which are used for vacuum work, are sealed by using a release film (not shown) during lamination, .

The panel that has been demolded from the forming die 10 is subjected to a finishing operation so as to conform to the standard or shape, and unnecessary portions are cut.

At this time, the molded product demolded from the forming die 10 is formed into the shape of the product to be molded, but since the edge is not finished cleanly, the end of the edge is cut to form a complete shape panel.

Hereinafter, the present invention will be described in detail.

1 is a view showing a manufacturing process according to a method for manufacturing a phenol laminate panel for internal and external use according to the present invention. The preparation of the mold 10 and the application of the releasing agent S1 → the application of the gel coat 30 S2 → the curing of the gel coat 30 S3 the installation of the space mat 40 and the UP resin impregnation step S4, → UP resin is impregnated with glass fiber 50 → S5 → UP resin and glass fiber curing step S6 → Phenol resin application and glass fiber 70 are installed Step S7 → Vacuum film 80 is installed, (S8), followed by curing and demolding (S9), a phenol laminate panel for internal and external use using a dermal resin and a phenolic resin is produced.

2 is a cross-sectional view of a phenol laminate panel according to an embodiment of the present invention. As shown in FIG. 2, a mold release agent 20 is applied to a forming mold 10, The gel coat 30 of 0.1 to 0.5 mm is applied and cured to form a gel coat layer.

UP resin is applied to the gel coat layer, a space mat (40) is installed in the UP resin, and the space mat (40) is impregnated and impregnated with a roller or a brush to form a space mat layer.

One 300 to 600 mesh is laminated on the space mat 40, and a glass fiber layer 50 is formed thereon to form a glass fiber layer.

The dried glass fiber 50 is laminated on the upper side of the glass fiber layer by the thickness of the glass fiber immersed in the UP resin in the lower part. That is, the glass fiber is laminated with 1/2 of the glass fiber immersed in the UP resin, and 1/2 of the dried glass fiber is cured.

In addition, a phenol resin is applied to the uppermost surface of the glass fiber which is not immersed in the UP resin, followed by setting the glass fiber 70 and curing.

 After the glass fiber 70 is laminated and fixed after applying the phenol resin as described above, the vacuum film 80 is covered, the rim is sealed, and the vacuum is applied to form a panel.

The inner and outer phenol laminate panels using UP resin and phenol resin manufactured as described above are used as phenol laminate panels for use in electric cars, trains, doors of buildings, indoor and outdoor buildings, and the like.

FIG. 3 is an exemplary view showing a tent product manufactured by the panel manufacturing method of the present invention, which is a panel product model diagram (90) of a movable prefabricated house manufactured by the manufacturing method of FIG. 1, A panel product model diagram 90 of a movable prefabricated house can be manufactured in large quantities using a phenol laminate panel manufactured according to the manufacturing process sequence of FIG.

In other words, for example, when a movable prefabricated house is installed, a panel made of several pieces can be manufactured, and a model of the form shown in FIG. 3 can be easily installed in a house and can be easily disassembled and installed in another place.

Particularly, since the present invention is an FRP product, it is used semi-permanently and can be installed in a camping village which is popular in recent years because it is easy to repetitively disassemble the installation mill.

According to the panel of the present invention thus formed, a panel can be manufactured by polymerizing UP resin and phenol resin, thereby providing a fire-resistant nonflammable inner and outer panel that has the same strength as a steel plate and can display various colors.

In addition, the present invention has an advantage in that a gel coat of a desired color is selected at the time of molding the gel coat 30, thereby providing a built-in panel of a desired color to a consumer in the future.

10: Molding mold 20: Mold release agent
30: gel coat 40: space
50: glass fiber 60: phenol resin
70: glass fiber 80: vacuum film
90: Panel product model diagram

Claims (5)

Applying and curing a gelcoat of a selected color to the surface of the mold surface to which the mold release agent is applied;
Placing a space mat on the gel coat layer and impregnating it with UP resin;
Impregnating glass fiber on a space mat impregnated with the UP resin;
Further laminating another glass fiber on the impregnated glass fiber, wherein the laminated glass fiber is laminated so that 1/2 of it is impregnated with the UP resin and the other half is not impregnated;
Applying a phenol resin to the upper surface of the glass fiber after laminating the lower layer of the glass fiber without being immersed in the upper layer, laminating the glass fiber on the upper surface, and curing the laminate for 1 to 2 hours;
Placing a vacuum film on the upper surface of the cured glass fiber layer, sealing the rim, vacuuming and curing for 3 to 5 hours;
And a step of finishing the edge of the inner and outer phenol laminate panel cured after the vacuum to complete the phenol laminate panel. The method of claim 1, wherein
The step of laminating and curing the glass fiber so as to be impregnated with the UP resin from the lower part and not impregnating the other half with the UP resin is performed by using the glass fiber impregnated in the UP resin 40 to 70 wt% To 60% by weight based on the total weight of the phenol resin. The method according to claim 1,
Wherein the gel coat of the selected color is applied in a thickness of 0.1 to 0.5 mm. ≪ RTI ID = 0.0 > 11. < / RTI > The method according to claim 1,
Wherein the phenol laminate panel is formed by polymerization of an UP resin and a phenol resin. A phenol laminate panel for internal and external use using a dermal resin and a phenolic resin produced by the manufacturing method of claim 1.

Images