JP2002337158A - Fiber reinforced plastic molded product and method for manufacturing the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a fiber reinforced plastic molded product not imparting dazzlement by reflection even with respect to the incidence of solar rays or the like, and to provide a method for manufacturing the same. SOLUTION: In the fiber reinforced plastic molded product, at least one surface is an uneven surface wherein projected and recessed parts are arranged at random, and formed into a rough surface wherein the average difference between the heights of the projected and recessed parts is not less than 0.5 mm.

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 and a method for producing the same, and more particularly, to a fiber-reinforced plastic molded article having a rough surface capable of preventing dazzling due to reflection of sunlight or the like, and the same. The present invention relates to a method for producing a fiber-reinforced plastic molded product that can be easily molded.

[0002]

2. Description of the Related Art Conventionally, a fiber-reinforced plastic molded product has been
Utilizing features such as easy formation of complicated curved surfaces,
The surface was generally a smooth glossy surface. In addition, even when a rough surface having irregularities is formed, for example, the method relies on a method of forming an irregular surface by painting after molding, and the irregularities of the formed irregular surface are shallow,
In general, the pattern was regular or periodic.

[0003] Recently, the use of fiber-reinforced plastic moldings has expanded, and they have also been used for applications in the construction and civil engineering fields, such as installing large-area moldings outdoors. When installed in a location, there is a risk of dazzling passers-by and nearby residents due to the reflection of sunlight and the like. As described above, for example, even if an uneven surface is formed by painting after molding, there is a limit to the uneven height (depth) of the uneven surface that can be formed by painting, and only shallow unevenness can be formed.
The dazzling prevention performance by preventing reflection of sun rays and the like was insufficient. In addition, most of the uneven surface formed has a regular pattern or a periodic pattern, so that the diffuse reflection performance of sunlight or the like is insufficient. It was enough.

[0004]

SUMMARY OF THE INVENTION Accordingly, an object of the present invention is to solve the above-mentioned problems and to provide a fiber-reinforced plastic molded article which does not give glare due to reflection even when sunlight or the like enters. It is to provide a manufacturing method thereof.

[0005]

Means for Solving the Problems In order to solve the above-mentioned problems, a fiber-reinforced plastic molded article according to the present invention has at least one surface having an uneven surface in which convex portions and concave portions are randomly arranged, and an average surface. 0.5m height difference between typical convex and concave
m or more.

[0006] A rough surface having an average difference in height between a convex portion and a concave portion of 0.5 mm or more as described above is difficult to form by a conventional coating method. It cannot be formed without a special method intended to form a surface.

[0007] Such a rough surface can constitute a light irregular reflection surface and / or a light absorption surface, and has irregularities in which projections and depressions are randomly arranged with respect to the incidence of sunlight or the like. Appropriate irregular reflection on the surface and / or appropriate absorption of light effectively prevents glare from the reflected light. In other words, excellent dazzling prevention is achieved by the uneven surface in which the convex portions and the concave portions are randomly arranged and the rough surface in which the average height difference between the convex portions and the concave portions is 0.5 mm or more. The effect is obtained.

[0008] The fiber-reinforced plastic forming the rough surface as described above may be colored by a pigment contained in the plastic. By coloring, in addition to the irregular reflection performance due to the random uneven surface shape, appropriate light absorption performance can be provided, and dazzling due to reflected light is more effectively prevented.

The fiber-reinforced plastic forming a rough surface is composed of at least two layers, a layer for forming a rough surface and a layer for obtaining strength and rigidity. Is preferred. With such a configuration, both the characteristics of the excellent anti-glare performance targeted by the present invention can be easily achieved satisfactorily while securing the target strength and rigidity. A layer for forming a rough surface;
By separating the layer for obtaining the strength and rigidity, the orientation of the reinforcing fibers for obtaining the strength and rigidity can be prevented from being locally bent due to the influence of surface irregularities, preventing the strength and rigidity from being reduced. can do.

[0010] The fiber-reinforced plastic forming the rough surface may have a colored layer on the outermost side for the purpose of improving the appearance. By adopting a configuration in which the entire resin is colored by the pigment contained in the fiber-reinforced plastic described above, or a configuration in which the outermost layer has a colored layer, deterioration of the resin due to ultraviolet rays is suppressed to only a small portion of the surface. And durability is also improved. Such a colored layer may be formed by any method, for example, by spraying two or more kinds of paint droplets having different colors.

The fiber-reinforced plastic having a multilayer structure and forming a rough surface is preferably formed integrally regardless of the number of layers constituting the plastic. by this,
Good moldability and mechanical properties of the entire fiber-reinforced plastic molded product are ensured.

The fiber-reinforced plastic molding according to the present invention may have a so-called sandwich structure. For example, a sandwich structure having a sandwich structure composed of a core material and a fiber-reinforced plastic skin material located on both sides of the core material, wherein at least one skin material is formed of the above-described fiber-reinforced plastic molded product. A fiber-reinforced plastic molded article having a portion can be obtained. In this case, the core material and the fiber-reinforced plastic skin material located on both sides of the core material are preferably formed integrally, so that the formability and mechanical properties of the entire fiber-reinforced plastic molded product are also good. Is secured.

A method for producing a fiber-reinforced plastic molded product according to the present invention is a method for molding a fiber-reinforced plastic molded product having the above-described structure into a tick, wherein at least one surface has the above-mentioned predetermined rough surface shape. The method is characterized in that a roughened surface is formed by transferring a concave-convex surface of a mold to a molded product by using a molding die in which an inverted concave-convex surface is processed. In this way, the difference in height between the convex portion and the concave portion can be increased by transferring the unevenness of the mold and forming the uneven surface instead of the later coating.

In this method, the uneven surface of the mold is
It is preferable to be formed of a material having elasticity that can follow the deformation. Since the uneven surface of the mold is made of an elastic material, a large force is not required at the time of demolding, and the mold and the molded product are not chipped. Further, it is preferable that the uneven surface of the mold is formed of a material having a lower elastic modulus than the core material included in the molded product. Thereby, a molding method (for example, SCR
Even when the IMP method is used, the unevenness of the mold does not affect the layer for obtaining the strength and rigidity, and a phenomenon such as a decrease in strength is prevented.

[0015]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Preferred embodiments of the present invention will be described below with reference to the drawings. 1 and 2
Shows a fiber-reinforced plastic molded product according to one embodiment of the present invention. In FIG. 1, reference numeral 1 denotes an entire fiber-reinforced plastic molded product, for example, a fiber-reinforced plastic molded product having a structure suitable as a soundproof wall or a partition wall. Reference numeral 2 denotes a wall main body, and reference numeral 3 denotes a mounting portion to another building or pedestal. In this embodiment, in particular, the wall main body 2 has the configuration of the fiber-reinforced plastic molded product according to the present invention, and at least one surface (outer surface) is an uneven surface in which convex portions and concave portions are randomly arranged. In addition, it is formed on the rough surface 4 in which the average difference between the heights of the convex portions and the concave portions is 0.5 mm or more.

In the present embodiment, the wall main body 2 is
And a sandwich structure portion composed of a fiber-reinforced plastic skin material 6 located on both sides of the core material 5. 4 is formed. The core member 5 and the fiber-reinforced plastic skin members 6 located on both sides of the core member 5 are integrally formed. The material of the core material 5 is not particularly limited, but from the viewpoint of securing the lightness as a whole, a material having desired strength and rigidity and as small as possible specific gravity or apparent specific gravity is preferable. For example, a foam (for example, rigid foamed polyurethane), wood, a honeycomb structure, or the like can be used.

In the present embodiment, at least the fiber-reinforced plastic layer forming the rough surface 4 has at least
It has two layers, a layer 7 for the purpose of forming the rough surface 4 and a layer 8 for the purpose of obtaining strength and rigidity. For the purpose of improvement, also equipped with resin degradation prevention performance due to ultraviolet rays,
A coloring layer 9 is provided.

Layer 8 intended to obtain strength and rigidity
Consists of a layer containing reinforcing fibers in the form of one-way, two-way, woven fabric or the like, and the layer 7 intended to form the rough surface 4 consists of a layer containing a mat or the like of the reinforcing fibers, for example. The colored layer 9 is composed of, for example, a gel coat layer or a pigment-containing resin layer of two or more colors. The colored layers of two or more colors can be formed by spraying paint droplets of two or more different colors using, for example, an air gun. The type of the reinforcing fiber is not particularly limited, and can be appropriately selected from carbon fiber, glass fiber, aramid fiber, unsaturated polyester fiber, inorganic fiber, and the like according to the intended use, and these can be used in combination. In addition, the type of the matrix resin is not particularly limited, and a thermoplastic resin can be used in addition to a thermosetting resin such as an epoxy resin, a vinyl ester resin, and a phenol resin.

An uneven surface in which convex portions and concave portions are randomly arranged, and an average difference in height between the convex portion and the concave portion is 0.5 mm
In order to form the rough surface 4 as described above, it is preferable to mold using a mold having an uneven surface in which the shape of the rough surface 4 is reversed in advance. With a conventional coating method, it is difficult to form a rough surface having the unevenness depth specified in the present invention. By transferring the uneven surface of the mold to the molded product, a rough surface having the uneven depth defined in the present invention can be easily formed.

The uneven surface of the molding die is preferably formed of a material having elasticity capable of following deformation, especially when the mold is released. As such an uneven surface forming material, for example, a material having a relatively low hardness is preferable. Urethane rubber or the like can be used.
Further, when the core material 5 is included in the molded product as described above,
It is preferable to be formed of a material having a lower elastic modulus than the core material 5. By forming the concave-convex surface of the molding die with such a material, as described above, a large force is required at the time of demolding, and it is also prevented that the die or the molded product is chipped,
Further, adverse effects such as deformation on the molded product side at the time of demolding are prevented.

As a method for molding the fiber-reinforced plastic molded article according to the present invention, any of the general fiber-reinforced plastic molding methods such as a hand lay-up method and an autoclave method can be used. Also, each member molded by a continuous molding method such as a pultrusion method,
After cutting to an appropriate size, it can be formed by assembling and joining. However, preferably, integral molding is easy,
In addition, the so-called RTM method and the RIM method, which can easily achieve weight reduction by increasing the fiber content, and the integral molding method (SCRI, in which a molding material is depressurized and a diffusion material of an injection resin is arranged at the same time)
It is desirable to employ a molding method of injecting a liquid plastic into a cavity in which reinforcing fibers are arranged, such as an MP method.

[0022]

DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, a description will be given based on more specific embodiments. A fiber-reinforced plastic molded product as shown in FIGS. 1 and 2 was produced. As a mold for transferring an uneven surface, a sheet having unevenness with an average depth of about 3 mm formed of urethane rubber having a hardness of 60 degrees by a hardness measurement method specified in JIS-K-6301. , A silicone-based release material was applied to the surface of the sheet. Thereafter, a gel coat containing a polyester resin as a main component was applied using an air gun so as to be arranged in three colors of paint particles of white, black, and brown, and was once cured.

Further, for forming an outer surface having a rough surface, a layer intended for forming a rough surface is formed, so that one ply of a glass fiber chopped strand mat and strength and rigidity are obtained. In order to form the desired layer, one ply of a 0/90 ° woven fabric of glass fiber and one ply of a 0 ° woven fabric of carbon fiber are laminated, and a 30-fold expanded rigid polyurethane foam is used as a core material. For forming the inner surface side having a surface, one ply of glass fiber 0/90 ° woven fabric is laminated to form a non-rough surface skin layer,
The whole was integrally formed by the SCRIMP method described above. The matrix resin was an unsaturated polyester resin, and was colored gray using a pigment.

The obtained fiber-reinforced plastic molded product is
It has a design surface similar to a brick,
It was possible to prevent dazzling without reflecting light in a certain direction. In addition, despite the use of a mold having deep irregularities, the mold removal was extremely easy, and no scratches or chips were generated on the obtained molded article or the mold after the mold release.

When the obtained fiber-reinforced plastic molded product is cut and its cross section is observed, a layer for forming a rough surface is provided immediately inside the rough surface, so that the purpose is to obtain strength. The reinforcing fiber of the layer to be kept was almost linear without being affected by the uneven surface. As a result, physical properties such as tensile strength and elastic modulus could be expressed as designed.

Also, using this molding technique, a soundproof wall for a railway viaduct having a rough surface defined by the present invention and having the form shown in FIGS. 1 and 2 was formed and installed on a viaduct experimentally. However, even on the side road under the viaduct, there was no dazzling sunlight reflection, and the soundproof wall was considered for residents along the road.

[0027]

As described above, according to the fiber-reinforced plastic molded article of the present invention, even if direct sunlight is incident on the surface thereof, it diffuses the sunlight to give dazzle to a third party. And a fiber-reinforced plastic molded article without the same can be obtained. In other words, as a building or structure,
The fiber-reinforced plastic molded product can be applied to those installed outdoors.

Further, by coating the surface with a colored layer such as a gel coat or by adding a pigment to a matrix resin, not only the appearance of the molded article is improved, but also the molding of the fiber-reinforced plastic molded article by ultraviolet rays. Deterioration can be minimized and can be made more suitable for outdoor use.

Further, by providing a layer for forming a rough surface, the linearity of the reinforcing fibers contained in the layer for obtaining strength and rigidity can be maintained, and as a result, the original fiber can be maintained. The surface of the fiber-reinforced plastic molded product can be made a desired rough surface without affecting the strength and rigidity.

Further, by using a resilient material capable of following a large deformation in a mold for transferring an uneven surface,
Even on a surface having deep irregularities, a target molded product can be easily obtained without requiring a large force for demolding or damaging the mold or molded product during demolding.

[Brief description of the drawings]

FIG. 1 is a perspective view of a fiber-reinforced plastic molded product according to one embodiment of the present invention.

FIG. 2 is an enlarged sectional view of a portion II in FIG.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Fiber-reinforced plastic molded article 2 Wall main body 3 Mounting part 4 Rough surface 5 Core material 6 Skin material made of fiber-reinforced plastic 7 Layer for forming rough surface 8 Layer for obtaining strength and rigidity 9 Colored layer

 ────────────────────────────────────────────────── ─── Continuing on the front page (72) Inventor Shintaro Tanaka 1515 Tsutsui, Matsumae-cho, Matsumae-cho, Iyo-gun, Ehime F-term in the Ehime Plant of Toray Industries, Inc. (reference) 4F100 AD11C AG00B AG00C AG00E AK41A AK44B AK44C AK44E AK51D BA05 BA07 BA10A CA13A DD07B DH02B DH02C DH02E EJ01D GB07 HB00A JK01C JL10A JN30 4F204 AA41 AD04 AD11 AD16 AD17 AD20 AE06 AE10 AF01 AG03 AG05 AG20 AH43 EA03 EA04 EB01 EB11 EB22 EB29 EF05 AG03 A05 AD16 AE05 AE05 AE05 HM05 HT04 HT12 HT24 HT28

Claims (12)

[Claims] At least one surface is formed as a rough surface in which protrusions and recesses are randomly arranged and a rough surface having an average difference in height between the protrusions and the recesses of 0.5 mm or more. A fiber-reinforced plastic molded product, characterized in that: 2. The fiber-reinforced plastic molded article according to claim 1, wherein the rough surface constitutes a light irregular reflection surface and / or a light absorption surface. 3. The fiber-reinforced plastic molded article according to claim 1, wherein the fiber-reinforced plastic forming the rough surface is colored by a pigment contained in the plastic. 4. A fiber-reinforced plastic forming a rough surface is composed of at least two layers: a layer for forming a rough surface and a layer for obtaining strength and rigidity. The fiber-reinforced plastic molded product according to any one of claims 1 to 3, characterized in that: 5. The fiber-reinforced plastic forming a roughened surface has a colored layer for improving appearance on the outermost side thereof, according to claim 1. Fiber reinforced plastic molded product. 6. The fiber-reinforced plastic molded article according to claim 5, wherein the colored layer is formed by spraying two or more kinds of paint droplets having different colors. 7. The fiber according to claim 4, wherein the fiber-reinforced plastic forming the rough surface is integrally formed regardless of the number of layers constituting the fiber. Reinforced plastic moldings. 8. A sandwich structure comprising a core material and fiber-reinforced plastic skin materials located on both sides of the core material, wherein at least one skin material is provided.
A fiber-reinforced plastic molded article having a sandwich structure, comprising the fiber-reinforced plastic molded article according to any one of claims 1 to 7. 9. A fiber-reinforced plastic molding having a sandwich structure according to claim 8, wherein the core material and the fiber-reinforced plastic skin material located on both sides of the core material are integrally formed. Goods. 10. A method of forming a rough surface by using a molding die having at least one surface processed with a concave and convex surface obtained by inverting a predetermined rough surface shape, and transferring the concave and convex surface of the mold to a molded product. A method for producing a fiber-reinforced plastic molded product according to any one of claims 1 to 9. 11. The method for producing a fiber-reinforced plastic molded product according to claim 11, wherein the uneven surface of the mold is formed of a material having elasticity capable of following deformation. 12. The fiber-reinforced plastic molded article according to claim 10, wherein the uneven surface of the mold is formed of a material having a lower elastic modulus than a core material included in the molded article. Production method.