JPH02273223A - Fiber reinforced resin molding sheet and method for molding fiber reinforced resin - Google Patents

Abstract

PURPOSE:To easily form a uniform and non-irregular surface resin layer by preliminarily laminating a surface resin layer for smoothly and beautifully treating the surface of a molded product to the fiber reinforced resin layer of a molding sheet. CONSTITUTION:A surface resin layer 20 is called a gel coat layer 20 and can be formed using a composition consisting of various resins and additives corresponding to the properties or characteristics imparted to the surface of a molded product. For example, a composition containing the same resin material as a fiber reinforced resin layer 10 but not containing a reinforcing material, one wherein a usual colorant is added to a resin material or one wherein a surface mat or a nonwoven fabric composed of an org. fiber is laminated to the resin material is designated. A fiber reinforced resin molding sheet S composed of the above mentioned materials is prepared by a method wherein a coating film 30 is laminated to the surface resin layer 20 and, after the surface resin layer 20 is thickened, the fiber reinforced resin layer 10 is laminated to the surface resin layer 20 and the coating film 30 is further laminated thereto.

Description

[Detailed Description of the Invention] [Field of Industrial Application] The present invention relates to a sheet for molding fiber-reinforced resin and a method for molding fiber-reinforced resin. The present invention relates to a molding sheet for manufacturing a desired molded product by shaping along a mold and then curing it, and a method for molding a fiber reinforced resin using the molding sheet.

[Conventional technology]

Many methods are known for manufacturing fiber-reinforced resin molded articles, such as hand lay-up method, spray molding method, mold molding method, and vacuum molding method.

Figure 4 shows an outline of the vacuum forming method, in which fiber-reinforced resin molding sheets are made by adding reinforcing materials such as glass fibers and carbon fibers to a liquid thermosetting resin such as Boessel resin. A molding sheet S is prepared in advance, and this molding sheet S is placed on a female mold m or a male mold m (the state shown by the two-dot chain line in FIG. 4), and the molding sheet S is placed on the mold surface of the mold m. By applying vacuum suction from the vacuum suction port V, the forming sheet S is shaped so as to follow the mold surface, and then hardened to form the mold M.
When taken out, a molded article M having a desired shape can be obtained as shown in FIG.

This vacuum forming method has a simple structure for the mold m, does not require much mold precision, and is expected to be widely adopted in various applications as a method that can efficiently produce molded products M with relatively high precision. There is.

The fiber-reinforced resin molded product M manufactured by the vacuum forming method may have unevenness due to glass fibers, etc. on the surface, so if it is necessary to improve the appearance or obtain a smooth surface, it is necessary to The surface of the molded article M is covered with the surface resin C by laminating the surface resin C made of synthetic resin or the like without reinforcing material on the surface by means such as painting. The surface resin C is also provided to improve the coloring, texture, and other surface characteristics of the surface of the molded product M.

[Problems to be Solved by the Invention] However, the conventional molding method as described above involves two steps: forming a fiber-reinforced resin molded product by shaping and curing, and covering the surface of the molded product with a surface resin. This method has the disadvantage that the entire manufacturing time is long. Furthermore, it is difficult to uniformly and evenly cover the surface of a molded article with a three-dimensional uneven surface with a surface resin, and there is also the problem that the surface resin cannot sufficiently improve the characteristics of the surface of the molded article.

Therefore, an object of this invention is to provide a fiber-reinforced resin molding sheet for easily and economically manufacturing a fiber-reinforced resin molded product whose surface is satisfactorily covered with a surface resin, and a fiber-reinforced resin molding sheet using the above-mentioned molding sheet. The object of the present invention is to provide a method for molding resin.

[Means to solve the problem]

A fiber-reinforced resin molding sheet according to claim 1 of the present invention that solves the above problems is a molding sheet that is shaped and hardened along the surface of a mold to form a fiber-reinforced resin molded product. A surface resin layer is laminated in advance on the surface of the fiber-reinforced resin layer that constitutes the surface of the molded product.

FIG. 1 shows an example of a fiber-reinforced resin molding sheet according to the present invention, and will be described with reference to this figure.

The fiber-reinforced resin layer 10 constituting the molding sheet S is formed by a method similar to that used in so-called sheet molding, such as a normal vacuum molding method. As the resin material, any ordinary liquid thermosetting resin can be used. in particular,
Examples include unsaturated polyester resins, epoxy resins, polyurethane resins, and epoxy (meth)acrylate resins. Ordinary reinforcing fibers can also be used as reinforcing materials for resin materials. Specifically, glass, carbon, metal,
Examples include fiber rovings, mats, swirl mats, and nonwoven fabrics made of Kepler (trade name, aramid resin), Tetron (trade name, polyester resin), and the like.

The surface resin layer 20 is also called a gel coat layer in boat fishing, and can be made of various resins and additives depending on the properties and characteristics to be imparted to the surface of the molded product. For example, the same resin material as the fiber-reinforced resin layer 10 but without reinforcing material, a resin material with a normal coloring agent added, a surface mat layered on the resin material, a non-woven fabric made of organic fibers, etc. Examples include laminated ones. In order to improve the handling properties when cutting and transporting the molding sheet, the viscosity of the surface resin layer 20 may be adjusted, so-called thickening. It is preferable to thicken the viscosity when it contains only

As the viscosity increasing means, common means for increasing the viscosity of synthetic resin materials, such as the use of a thickening agent, light irradiation, and heating, can be employed. The surface resin layer 20 is provided on at least one side of the fiber-reinforced resin layer 10, but it can be provided on both sides if necessary.

It is preferable that a covering film 30 is laminated on at least one side of the fiber-reinforced resin molding sheet S in which the fiber-reinforced resin layer 10 and the surface resin layer 20 are laminated. Vacuum suction or pressure when molding S into sheets can be used to prevent air bubbles from entering the resin material, to prevent the molding sheets S from sticking to each other when stacked, and to prevent the handling of the molding sheets S. Used for the purpose of facilitating.

The covering film 30 may be provided only on the surface where air bubbles are likely to enter during sheet molding, or may be provided on both surfaces. The covering film 30 can be made of various thermoplastic resin films used in normal molding methods, but it is preferable to use a material that is not corroded by the resin materials of the fiber reinforced resin layer 10 and the surface resin layer 20. Specifically, nylon, vinylon, polyvinyl alcohol, etc. are used, and the thickness of the covering film 30 is preferably 5 to 50011 m, more preferably 10 to 100 m. Note that the covering film 30 is usually peeled off and removed from the surface of the molded product after the fiber-reinforced resin molding sheet S) has been molded.

Fiber-reinforced resin molding sheet S made of the above materials
In order to manufacture this, lamination means for ordinary synthetic resins and fiber-reinforced resins can be used. Specifically, for example, the following method is adopted.

One method is to laminate the covering film 30 and the surface resin layer 20, then thicken the surface resin j5i20, then laminate the fiber reinforced resin layer IO on the surface resin layer 20, and then add the covering film 30. Stack. After defoaming, thicken as necessary. Another method is to manufacture one in which a covering film 30 and a surface resin layer 20 are laminated and the surface resin layer 20 is added, and another in which a fiber reinforced resin layer 10 is laminated on another covering film 30, This is a method of manufacturing a fiber-reinforced resin molding sheet S by combining the two, and then thickening if necessary.

The method for molding a fiber-reinforced resin according to claim 2 is a method of molding a fiber-reinforced resin molded product by shaping and curing a fiber-reinforced resin molding sheet along a mold surface, the fiber-reinforced resin molding sheet As a method, a molding sheet with a surface resin layer laminated in advance on the surface of the fiber-reinforced resin layer that constitutes the surface of the molded product is used, and at the same time as the fiber-reinforced resin molded product is molded, the surface of the molded product is coated with the surface resin. Make sure to cover it with a layer.

FIGS. 2 and 3 show an embodiment of the molding method according to the present invention, and will be described with reference to each figure.

In the fiber-reinforced resin molding sheet S, the resin material is preferably thickened in order to improve handling workability, molding accuracy, and the like. As the viscosity increasing means, the same means as used for ordinary molding sheets can be employed. Specific examples include the use of thickeners such as MgO and isocyanate compounds, heating, and light irradiation.

The method of shaping the molding sheet S along the mold surface is as follows:
This can be carried out using the same molding equipment or means as used for molding ordinary fiber-reinforced resins. As mentioned above, such forming methods, that is, sheet forming methods, include vacuum forming, in which one side of the forming sheet is vacuum-suctioned and adsorbed along the mold surface to form the shape, and air pressure, etc., from one side of the forming sheet. There are two types of sheet forming methods: pressure molding, in which the sheet is pressed along the opposite side of the mold surface, and vacuum/pressure molding, in which vacuum suction and pressure are applied at the same time. Can be adopted.

Figure 2 shows the sheet forming method using vacuum forming.
Vacuum suction ports 41, 41 are provided at appropriate positions on the mold surface of the female mold 40, and on the mold 40,
The molding sheet S is arranged so that the surface resin layer 20 faces the mold surface (indicated by the two-dot chain line in the figure), and by vacuum suction from the vacuum suction port 41, the molding sheet S is placed in the mold 40. It is shaped along the mold surface.

The method for curing the shaped molding sheet S can be carried out in the same manner as the molding method for ordinary fiber reinforced resins. The curing method for the molding sheet S includes room temperature curing, heat curing, heat curing, etc. depending on the material of the resin material. Photocuring and the like are available, and any of these methods may be employed.

After the molding sheet S is cured, it is removed from the mold 40 to complete the molding. FIG. 3 shows a molded article M, in which a surface resin layer 20 covers the surface of a fiber-reinforced resin layer 10 having a predetermined shape. In addition, when the covering film 30 is laminated|stacked on the surface of the shaping|molding sheet S, after shaping|molding is complete|finished, the covering film 30 is peeled off and removed, and the fiber reinforced resin layer 10 and the surface resin layer 20 are exposed.

[For production]

If a molding sheet in which a fiber-reinforced resin layer and a surface resin layer are laminated in advance is used, the surface resin layer can be formed along the surface of the molded article simultaneously with the molding of the molding sheet.

〔Example〕

Next, specific embodiments of this invention will be described.

Example 1 - A fiber-reinforced resin molding sheet S having the structure shown in FIG. 1 was manufactured. That is, the surface resin layer 20 is laminated on one side of the fiber-reinforced resin 110, and the fiber-reinforced resin layer 10
A covering film 30 is laminated on the other surface and the surface of the surface resin layer 20, that is, on both surfaces of the molding sheet S.

As the surface resin N20, one having the following formulation was used. The following blending ratios are all in parts by weight: Unsaturated polyester resin (manufactured by Nippon Shokubai Chemical Co., Ltd., Evolac N-325)...100 parts Silicic anhydride fine powder...2 parts Titanium white
... 10 parts styrene ・
... 15 parts These materials were dispersed using a homomixer to obtain a material for surface resin Jif20.

A resin liquid prepared by blending 100 parts of the above surface resin material with 2 parts of MgO and 1 part of tert-butyl perbenzoate is applied onto the vinylon film that will become the covering film 30 to a thickness of 0.
After applying the resin so as to have a thickness of 80%, the resin was left at 40° C. for 18 minutes to increase the viscosity, thereby producing the surface resin layer 20. Next, unsaturated polyester resin (manufactured by Nippon Shokubai Chemical Co., Ltd., Eborasoku G-
105) Using a resin solution containing 1 part of tert-butyl perbenzoate in 100 parts, apply the resin solution and glass fiber (manufactured by Nittobo fi, MC-45) on the surface resin layer 20.
0A) A fiber-reinforced resin layer IO was produced by laminating five sheets.

Further, a covering film 30 made of a vinylon film was laminated on the fiber-reinforced resin layer 10, and then defoamed to obtain a molding sheet S.

A molding sheet S was molded using a vacuum molding device whose structure is schematically shown in FIG. Molding mold 40
The mold has vacuum suction ports 41 at the four corners of the bottom of the mold surface, and a female mold with an opening size of 200 x 500 mm and a depth of 501 m is formed. The mold temperature was 120°C. A fiber-reinforced resin molding sheet S was placed and fixed on top of the female mold so as to cover the opening, with the surface resin layer 20 side facing down. By suctioning the inside of the mold under reduced pressure through the vacuum suction port 41, the molding sheet S is deformed so as to adhere to the mold surface, and is shaped into a predetermined shape. After the shaped molding sheet S is cured by normal means, it is demolded and the coating film 30 covering both sides of the molding sheet S is peeled off, and a beautiful surface resin layer 20 is formed on the surface. A fiber-reinforced resin molded product M was obtained.

Example 2 Surface resin layer 20 is molded using materials and methods that are partially different from Example 1, and the differences from Example 1 will be mainly explained.
The formulation was as follows: Unsaturated polyester resin (manufactured by Nippon Shokubai Kagaku Kogyo +1m, Evolac N-325)...100 parts Silicic anhydride fine powder...2 parts Styrene
... 15 parts A resin material for the surface resin layer 20 was obtained from these materials in the same manner as in Example 1.

Using a resin solution containing 100 parts of this resin material, 1 part of MgO, and 2 parts of an ultraviolet sensitizer (manufactured by Ciba Geigy ■, Irgacure 651), Surf Ace Mat (manufactured by Nippon Sheet Glass ■, Microglass CFG-24) was used. The four layers were laminated on top of the vinylon film that would become the covering film 30, and heated at 40°C.
18, thicken, cover film 30 and surface resin! 20 were laminated. Next, on the surface resin layer 20, a resin liquid containing 100 parts of an unsaturated polyester resin (Evolac G-105, the same as in Example 1) and 2 parts of an ultraviolet sensitizer (Irgacure 651) is used. A fiber-reinforced resin layer 10 was formed by laminating five glass fibers (MC-450A, the same as in Example 1). Further, a vinylon film covering film 30 was laminated on the fiber-reinforced resin layer 10 and then foamed to obtain a fiber-reinforced resin molding sheet S.

The mold 40 used was the same as in Example 1. However, the mold temperature was 25°C. In the same manner as in Example 1, the molding sheet S was shaped by vacuum forming, and then an ultraviolet lamp was irradiated for 10 minutes to harden the resin material of the molding sheet S. If the mold is removed and the covering film 30 is peeled off, Example 1 is obtained.
Similarly, a fiber-reinforced resin molded product M having a beautiful surface resin layer 20 was obtained.

Example 3 - The composition of the surface resin layer 20 was as follows: Epoxy (meth)acrylate (manufactured by Nippon Shokubai Chemical Co., Ltd., Evolac RF-1002)...100 parts titanium white
... 10 parts From these materials,
A resin material for the surface resin layer 20 was obtained in the same manner as in Example 1.

To 100 parts of this resin material, 5 parts of toluene diisocyanate
Using a resin solution containing 1 part of tertiary butyl perbenzoate, 4 layers of Surf Ace mat (microglass CFG-24, the same as in Example 2) were coated with a coating film of 3 parts.
0 and was laminated on a polyvinyl alcohol film treated with a silicone mold release agent, and left at 40° C. for one day to thicken the viscosity, thereby obtaining a laminated layer of the covering film 30 and the surface resin layer 20. Next, on the surface resin layer 20, an epoxy (meth)acrylate resin (the above-mentioned Eborafuku RF-1
002) Glass fiber (Example 1
A fiber-reinforced resin layer 10 is formed by laminating five sheets of MC-450A), and a covering film 30 made of a polyvinyl alcohol film is placed on the fiber-reinforced resin layer IO.
are laminated and then foamed to form a fiber-reinforced resin molding sheet s-
I got it.

The mold 40 used was the same as in Example 1. However, the mold temperature was 130°C. In the same manner as in Example 1, the molding sheet S was shaped by vacuum forming, and then the resin material of the molding sheet S was cured by normal means. When the mold was removed and the covering film 30 was peeled off, a fiber-reinforced resin molded product M having a beautiful surface resin layer 20 was obtained as in Example 1.

〔Effect of the invention〕

According to the fiber-reinforced resin molding sheet and the fiber-reinforced resin molding method of the present invention described above, the surface resin layer for smoothing or beautiful surface treatment of the molded product is preliminarily applied to the fibers of the molding sheet. Since it is laminated on the reinforced resin layer, the surface resin layer can be formed on the surface of the molded product simply by molding the molding sheet.

Therefore, it is possible to eliminate the conventional and time-consuming process of forming a molding sheet consisting only of a fiber-reinforced resin layer and then forming a surface resin layer on the surface of the resulting molded product by means such as painting. In addition, since the fiber-reinforced resin layer and the surface resin layer are laminated in the form of a flat molding sheet, the surface resin layer can be formed easily compared to the conventional technology in which the surface resin layer is formed on the uneven surface of the molded product. It is much easier to form and can form a uniform and even surface resin layer,
It is possible to improve the appearance or surface properties of fiber-reinforced resin molded products.

[Brief explanation of drawings]

FIG. 1 is a sectional view of a fiber-reinforced resin molding sheet according to an embodiment of the present invention, FIG. 2 is a schematic sectional view showing an example of a molding method, FIG. 3 is a sectional view of a molded product, and FIGS. FIG. 5 is a schematic cross-sectional view showing a conventional molding method. 10...Fiber reinforced resin W120...Surface resin layer 3
0... Covering film 40... Molding mold S... Molding sheet M... Molded product agent Patent attorney Takehiko Matsumoto Figure 4 Figure 5

Claims (1)

[Scope of Claims] 1. A molding sheet for molding a fiber-reinforced resin molded product by shaping and curing along the mold surface, the sheet comprising: A fiber-reinforced resin molding sheet characterized by having a surface resin layer laminated in advance. 2. In a method of molding a fiber-reinforced resin molded product by shaping and curing a fiber-reinforced resin molding sheet along the mold surface, as the fiber-reinforced resin molding sheet,
Using a molding sheet with a surface resin layer laminated in advance on the surface of the fiber-reinforced resin layer that constitutes the surface of the molded product, the surface of the molded product is coated with the surface resin layer at the same time as the fiber-reinforced resin molded product is molded. A method for molding fiber-reinforced resin, characterized by covering the resin.