JPH0820034A - Manufacture of frp molded product and the frp molded product - Google Patents

Abstract

PURPOSE:To provide a method of manufacturing an inexpensive FRP molded product, in which a surface pattern can be varied without varying the surface shape of a molding die, the recessed and projected shape is not destroyed when the pattern is formed by using an emboss film and the positions of pattern sections are not varied to deviate, and also provide an FRP molded product thereof. CONSTITUTION:A heat-setting resin layer 2 is formed on one face of a film or a sheet, and the side of forming the resin layer 2 is placed to form a molding tool surface 3. A molded material 4 is overlapped on the film or the sheet, heated and pressurized, and then a molded material is released from a mold and the resin layer and the film or the sheet placed on the molding tool surface and adhering to the molded material are peeled off in a manufacturing method of an FRP molded product.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing an FRP molded product and an FRP molded product.

[0002]

2. Description of the Related Art Conventionally, a method for producing an FRP molded article having a pattern on the surface is such that a clear resin compound is laminated on the surface of a release sheet such as a release paper or a polyester sheet, a nylon sheet, etc. A method has been employed in which the release sheet is peeled off from the molded product after heating and pressing the sheet on which the agent is placed together with the molding material. Further, there is also a method in which a glass cloth or a glass fiber non-woven fabric impregnated with a thermosetting resin is patterned, and then a molded product is manufactured by pressurizing and heating together with a molding material.

[0003]

However, the release paper or release sheet is slippery in the mold, and the molding material is SM.
If the fluidity is high, such as C or BMC, a positional deviation occurs and the appearance of the molded product is deteriorated. When using a glass cloth impregnated with a thermosetting resin, although there is little misalignment, only planar patterning can be performed, and in order to create a surface-shaped pattern with unevenness, the mold itself must be uneven. It is necessary to provide.

On the other hand, although there is a method of using an embossed film as a method of imparting a pattern having irregularities on the surface without changing the mold, the irregularities are crushed by heat and pressure and a desired surface shape cannot be obtained.

The present invention has been made in view of the above problems, and FR without changing the surface shape of the molding die.
An inexpensive FRP molded article manufacturing method and FR in which the surface pattern of the P molded article can be changed, the uneven shape does not collapse even if an embossed film is used, and there is no risk of misalignment of the patterned part.
The purpose is to provide a P molded product.

[0006]

According to the present invention, a thermosetting resin layer is provided on one surface of a film or sheet, and the resin layer is placed so that the side provided with the resin layer is the surface of the mold. An FRP molded article, characterized in that after the molding material is overlaid on the molded article and heated and pressed, the molded article is taken out of the mold and the resin layer and the film or sheet placed on the surface of the molding die adhered to the molded article are peeled off. Is a manufacturing method.

As the film or sheet used in the present invention, those having heat resistance and peelability and insoluble in the thermosetting resin are appropriately selected. Specifically, a polyethylene terephthalate resin, a polyethylene resin, a polypropylene resin, a nylon resin, a polyester resin, a fluororesin or other plastic film, or a metal foil such as an aluminum foil, which is adhered alone or with another plastic film, A paper or plastic film surface coated with a releasable resin is used. The film or sheet can be processed variously depending on the pattern you want to show on the surface of the FRP molded product, and by embossing the uneven shape, it produces FRP molded products such as woodgrain, rock surface, tile tone, and abstract pattern. Or a matte FRP molded product can be manufactured by performing sandblasting. Of course, it is also possible to produce a glossy FRP molded product by using it while it is flat. The thickness of the film is 25 to 500μ in order to secure the handling property and to retain the shape after embossing.
It is preferably about m.

The resin used for the thermosetting resin layer is appropriately selected from those having heat resistance and releasability and not melting and softening when heated and pressed. Specifically, acrylic resin,
Examples thereof include urethane resin, epoxy resin and unsaturated polyester resin. The method of applying the thermosetting resin to the film or sheet may be spraying with a spray gun, brush coating, roll coater, curtain coater, casting or the like without any particular limitation. In addition, in order to improve the coating strength of the thermosetting resin layer as needed, paper, woven or non-woven fabric made of organic fibers (polyester resin fiber, acrylic resin fiber, etc.), woven fabric of inorganic fibers (glass fiber, etc.) Alternatively, a nonwoven fabric may be impregnated and laminated. The thickness of the thermosetting resin layer depends on the strength of the coating film and FR
The thickness is preferably about 50 to 400 μm in order to reduce the step difference at the parting portion which occurs when the thermosetting resin layer and the film or sheet are peeled from the surface of the P molded product.

The film or sheet provided with the thermosetting resin layer is used in a semi-cured state. This is because if it is completely cured, it tends to slip in the molding die during heating and pressing. Further, in the uncured state, it becomes sticky and the handleability becomes poor. The uncured here means that the shape is maintained, the handling property is good, the strength is such that the outflow or crack destruction does not occur, and the flexibility that can follow the mold shape having the surface pattern and joints of the uneven shape. The state of possession, specifically, the degree of cure 60 to 90%
Is preferred.

In a second aspect of the present invention, a patterning sheet having a thermosetting resin layer formed on one surface of a film or sheet and a thermosetting resin layer having a pattern formed on the remaining one surface is not patterned. The resin layer is placed so as to be the surface of the molding die, the molding material is overlaid on the film or sheet and heated and pressed, and then the molded product is taken out of the mold and placed on the surface of the molding mold attached to the molded product. A method for producing an FRP molded article, which comprises peeling off a resin layer and a film or sheet that have not been placed and are not patterned.

The material of the film or sheet, the type of thermosetting resin, and the method of applying the thermosetting resin used in the second invention are the same as those in the first invention. The thickness of the patterned pattern layer is preferably about 100 to 500 μm in order to maintain the strength of the coating film and to improve design properties such as depth. The patterned sheet is also used in an uncured state like the film or sheet provided with the thermosetting resin layer of the first invention, but the patterned thermosetting resin layer enables adhesion to the molding material. Must leave enough reactive groups to do so.

[0012]

According to the present invention, it is possible to manufacture an FRP molded product having a different design simply by changing the surface of the film or sheet without changing the surface shape of the molding die.
Moreover, by providing a thermosetting resin layer where the irregularities are normally collapsed during pressure heating, the irregular shape is maintained. Further, since the thermosetting resin layer is used in an uncured state, the resin has an appropriate tackiness at the time of heating and pressing, and the resin is brought into close contact with the molding die to prevent the positional deviation.

[0013]

【Example】

Example 1 As shown in FIG. 1, 100 parts by weight of an uncured unsaturated polyester resin was used as an accelerator on one surface of an embossed film 1 obtained by processing a polyethylene terephthalate (hereinafter referred to as PET) film having a thickness of 100 μm into an uneven shape. 0.5 parts by weight of cobalt and 1.0 parts by weight of a curing agent Permek N (trade name of NOF CORPORATION) were applied, and a semi-cured state was formed at room temperature to form a resin layer 2. After the embossed film 1 provided with the resin layer 2 is cut into a predetermined size, as shown in FIG.
BMC as a molding material 4 is placed on the embossed film 1 and the back mold 5 is tightened to apply pressure (1
20 kg / cm ² ) Pressurized (front surface mold: 150 ° C., back surface mold: 145 ° C.) and molded. Finally, the molded product 6 was taken out of the mold, and the resin layer 2 and the embossed film 1 which had already been cured were peeled off from the surface to obtain a molded product 6 made of BMC having a pattern of uneven shapes on the surface.

Example 2 As shown in FIG. 4, a resin layer 2 was formed in the same manner as in Example 1 on the glossy side of a matte film 7 obtained by sandblasting one side of a PET film having a thickness of 50 μm, and the other side. Colored and opaque unsaturated polyester resin 1 on the matte surface of
00 parts by weight, 0.5 part by weight of cobalt as an accelerator, and 1.0 part by weight of a curing agent Permec N (trade name of NOF CORPORATION) are applied by spraying to form a pattern layer 8 by spraying. After that, the patterned sheet 9 was semi-cured at room temperature. After cutting the patterning sheet 9 into a predetermined size, the patterning sheet 9 is placed so that the resin layer 2 side is in contact with the surface mold 3 in the same manner as in Example 1, and SMC as the molding material 4 is laid on it and pressed (100 kg). / Cm ² ) Heating (surface type: 15
(0 ° C., back mold: 145 ° C.) and molded. Finally, the molded product 10 was taken out, and the resin layer 2 and the matte film 7 were peeled off to obtain an SMC molded product 10 having a matte surface and a patterned layer of a colored resin.

Example 3 As shown in FIG. 6, a glass fiber nonwoven fabric 12 having a basis weight of 15 g / m ² was laid as a reinforcing fiber on the surface of a base film 11 made of a PET film having a thickness of 50 μm, and one end on this surface was formed. To 100 parts by weight of transparent uncured isophthalic acid-based unsaturated polyester resin, 1.0 part by weight of Perloyl TCP (trade name of NOF CORPORATION) as a curing agent and 4-methyl-2 as a chain transfer agent, 4 diphenylpentene-1 (α-methylstyrene dimer) was added to 0.2%.
The thermosetting resin 13 added with 5 parts by weight was placed in a lump form.
On the other hand, a PET film having a thickness of 100 μm was processed into a rock-shaped concavo-convex shape, one surface was sandblasted for matting, and the other surface was treated with corona discharge to prepare an embossed film 14. The end side of the corona discharge treated surface of the embossed film 14 is pressed against the block-shaped thermosetting resin 13, and then the embossed film 14 is pressed by the roller 15 from one end of the glass fiber nonwoven fabric 12 on the base film 11, The embossed film 14 was laid on the thermosetting resin 13 while the glass fiber nonwoven fabric 12 was impregnated while the thermosetting resin 13 was uniformly stretched. Further, the thermosetting resin 13 is placed in a lump form on one end of the matte-treated surface of the embossed film 14, and the thermosetting resin 1
The one side of the transfer film 17 made of PET film having a thickness of 50 μm and having a granite pattern 16 formed by patterning one surface with a soluble ink on 3 is pressed against the block-shaped thermosetting resin 13, Then, transfer film 17 to roller 1
The thermosetting resin 13 was superposed on the thermosetting resin 13 while being pressed from one end onto the embossed film 14 by 8 to uniformly stretch and degas. The patterning sheet 21 thus manufactured was polymerized for 30 minutes in a curing oven maintained at 70 ° C. At this time, the thermosetting resin 13
Is stopped at a curing degree of 80% by the action of a chain transfer agent. When the transfer film 17 is peeled off after the semi-curing is completed, a granite pattern is transferred onto the thermosetting resin 13.

After cutting the patterning sheet 21 from which the transfer film 17 has been peeled off into a predetermined size, the base film 11 is peeled off, and the patterning layer 19 is placed on top (on the side of the thermosetting resin layer 20) as shown in FIG. So that it touches the surface mold 3)
After placing, SMC as the molding resin material 4 is placed on the patterning sheet 21 so as to be in contact with the pattern layer 19, and the back surface mold 5 is tightened and pressurized (100 kg / cm ² ) and heated (front surface mold: 1
(50 ° C., back mold: 145 ° C.) and molded. Molded product 2
After releasing 2 from the mold, the resin layer 20 and the embossed film 14 are peeled off, and the surface has a matte-finished rock-faced uneven pattern, and the transparent resin layer has a granite pattern inside. I got 22. In an embodiment of the present invention,
Even if a molding material such as SMC or BMC flows into the surface of the pattern portion at the parting portion between the pattern portion and the non-pattern portion of the molded product, the molding material can be removed by peeling the resin layer and the film, It does not spoil the appearance of the parting off pattern.

[0017]

The present invention has the following effects due to the above configuration. 1) Since the thermosetting resin layer is used in a semi-cured state, the thermosetting resin layer has tackiness when placed on the molding die and can prevent the sheet or film from being displaced due to flow in the molding die. 2) By coating the thermosetting resin on one side of the film or sheet, the uneven shape is not crushed by heating and pressing. 3) It is possible to change the design of the molded product simply by replacing the film or sheet without changing the surface shape of the molding die, and it is possible to cope with small lot production because it is inexpensive.

[Brief description of drawings]

FIG. 1 is a cross-sectional view of an embossed film provided with a thermosetting resin layer used in the present invention.

FIG. 2 is a cross-sectional view of a molding die and a molding material showing a method for manufacturing a BMC molded product in Example 1.

FIG. 3 is a cross-sectional view of peeling an embossed film and a thermosetting resin layer from BMC molding.

FIG. 4 is a cross-sectional view of a patterning sheet used in the present invention.

FIG. 5 is a cross-sectional view in which a matte film and a thermosetting resin layer are peeled off from an SMC molded product manufactured in Example 2.

FIG. 6 is a cross-sectional view showing an example of a method of manufacturing a patterned sheet.

FIG. 7 is a cross-sectional view of a molding die and a molding material showing an SMC-made molded product manufacturing method in Example 3.

FIG. 8 is a cross-sectional view in which a matte film and a thermosetting resin layer are peeled off from an SMC molded product manufactured in Example 3.

[Explanation of symbols]

1. Embossed film 2. Resin layer 3. Surface mold 4. Molding material 5. Back surface type 6. Molding
7. Matte film 8. Pattern layer 9. Patterning sheet 10. Molded product 11. Base film 1
2. Glass fiber non-woven fabric 13. Thermosetting resin 1
4. Embossed film 15. Laura 16. Pattern 17. Transfer film 18. roller
19. Pattern layer 20. Resin layer 21. Patterning sheet 22. Molding

 ─────────────────────────────────────────────────── ─── Continuation of the front page (72) Inventor Nobuhiro Ikeuchi 1010 Ippongi, Toyama City, Toyama Prefecture Within Hitachi Chemical Unit Co., Ltd. (72) Hirofumi Izumi, 4-13-1, Higashimachi, Hitachi City, Ibaraki Hitachi Chemical Yamazaki Factory Co., Ltd.

Claims (4)

[Claims] 1. A thermosetting resin layer is provided on one side of a film or sheet, and the side provided with the resin layer is placed so as to be the surface of a mold, and a molding material is superposed on the film or sheet and heated and pressed. After that, the molded product is taken out of the mold, and the resin layer and the film or sheet placed on the surface of the mold adhered to the molded product are peeled off. 2. A patterning sheet in which a thermosetting resin layer is provided on one surface of a film or sheet, and a thermosetting resin layer having a pattern is formed on the remaining one surface of the film or sheet, and an unpatterned resin layer is formed in a molding die. Place it on the surface, stack the molding material on the top of the film or sheet, press it under heat, and then remove the molded product from the mold and pattern it on the surface of the mold attached to the molded product. A method for producing an FRP molded article, which comprises peeling off a resin layer and a film or sheet which are not formed. 3. The method for producing an FRP molded product according to claim 1, wherein the film or sheet has an uneven shape. 4. An FRP molded article obtained by the method for producing an FRP molded article according to claim 1, 2.