JPH0363930B2 - - Google Patents

Description

[Detailed Description of the Invention] [Industrial Application Field] The present invention is directed to a comparatively thick and cold-curing type
This article relates to a manufacturing method and equipment for FRP molded products.

[Conventional technology]

Conventionally, FRP molded products, which have a wall thickness of 5 mm or more to create texture and volume, have a three-layer structure: a back layer with internal glass fiber, a translucent or transparent intermediate layer, and a transparent layer. The middle layer works to give the color depth. The mold for this FRP molded product is
It consisted of a lower mold and a plurality of upper molds that could be attached to and removed from the lower mold by clamps and separately covered each molding surface of the lower mold.

[Problem to be solved by the invention]

By the way, in order to mold an FRP molded product using the mold mentioned above, first, a transparent layer is applied to the molding surface of the lower mold and cured, and then the lower mold is connected at its ends with several clamps. A sealing material is filled between the ends of the upper mold to separate and surround the molding space and prevent resin leakage, and then a resin is applied to form an intermediate layer in the molding space. Pour the material. Next, after the intermediate layer is cured, all the upper molds are removed from the lower mold, and then a back layer is formed by a hand lay-up method or a spray-up method.
After this back layer is completely cured, it is removed from the mold.

However, since the number of upper molds increases, manpower is required when molding the intermediate layer. Since the number of clamps and the number of places to fill with sealing material are extremely large, the work is extremely troublesome, and no increase in productivity can be expected. If a number of molds are used to improve productivity, the number of upper molds will be very large, which will easily lead to confusion. Demolding the upper mold is troublesome. etc., causing various problems.

The present invention has been made in view of the above-mentioned conventional circumstances, and its purpose is to easily and reliably produce thick-walled, high-quality cold-curing FRP molded products using a small number of molds. The purpose of the present invention is to provide a method for manufacturing FRP molded products and an apparatus therefor.

[Means to solve the problem]

The technical measures taken to achieve the above objective are as follows.

In the first invention, (a) a transparent layer is applied to the molding surface of the lower mold of a mold consisting of three molds that can be matched, consisting of a middle mold, a lower mold, and an upper mold having air vent holes, and then cured; After that, the middle mold is mold-aligned to form an intermediate layer in the molding space, and the molding material is poured into the molding space, and the upper mold is mold-aligned. (c) After natural curing, lifting the middle mold and the upper mold while pumping air to the molding surface of the middle mold, and removing the middle mold and the upper mold. (d) Applying resin-impregnated glass fiber to the molded body; (e) After curing the glass fiber, molding the lower mold. The gist is to sequentially perform the process of demolding the FRP molded product by pumping air to the surface.

In the second invention, a mold is made up of three molds that can be matched together, consisting of a middle mold, a lower mold, and an upper mold having an air vent hole;
A vibration table on which the mold is installed, a mold lifting means provided in the middle mold for removing the middle mold and the upper mold from the lower mold, and a compressor for pumping air to the molding surface of the lower mold and the molding surface of the middle mold. The gist is that the system is equipped with an air supply means.

[Effect]

According to the above technical means, a thick cold-curing FRP molded product is manufactured using three molds consisting of a lower mold, a middle mold, and an upper mold.

〔Effect of the invention〕

Since the present invention is constructed as described above, it has the following advantages.

(1) First invention - Relatively thick but high-quality FRP molded products can be produced without any need for clamping the mold, filling with sealant, or the troublesome work of attaching and removing molds one by one. , can be manufactured easily and reliably. Moreover, since only three molds are used, inventory management is very easy and production costs are low.

(2) Second invention ●A manufacturing device with a simple structure that manufactures the above-mentioned high-quality FRP molded product without using many molds can be provided.

〔Example〕

Next, embodiments of the present invention will be described based on the drawings.

The first invention and the second invention will be explained in detail based on the first invention.

Γ Pre-process of the first process This process is performed by the manufacturing equipment 10 of the FRP molded product A.
0.

The manufacturing apparatus 100 includes a mold 1 consisting of an upper mold 11, a middle mold 21, and a lower mold 31, a mold lifting means 3 for the middle mold 21, a molding surface 21' of the middle mold 21, and a lower mold 3.
It consists of compressed air supply means 4 and 5 that supply air to the molding surface 31' of the mold 1, and a vibration table 51 that supports the mold 1.

The mold 1 is made up of the three molds to be matched, that is, the upper mold 11, the middle mold 21, and the lower mold 31.
A wide molding space 41 for FRP molded product A is configured.

In this embodiment, the object of the FRP molded product A is a bathtub, and the molding space 41 is shaped to match the bathtub.

The upper mold 11 has an air vent hole 2 in the center.

The middle mold 21 has a molding recess 6 large enough to secure a molding space 41 between it and the molding surface 31' of the lower mold 31.
It has a hat-shaped cross section, and a fitting hole 7 for the upper mold 11 is provided at the top.

The lower mold 31 has a hat-shaped cross section like the middle mold 21 so as to secure a molding space 41 between the upper mold 11 and the middle mold 21.

The mold lifting means 3 lifts the lower mold 3 in the middle mold 21.
Flange portion 21-1 corresponding to collar portion 31-1 on one circumference
It is composed of bolts screwed onto each side so as to be movable up and down, and the lower end is brought into contact with the engagement surface of the lower die 31.

The compressed air supply means 5 for the lower mold 31 is
1, an air supply hose 15 that communicates with the hole 14, a check valve 16 that opens when raised by air pressure from the hose 15, and the hose. 15 and a compressed air supply device (not shown).

The check valve 16 has a valve body 16'' fixed to the upper end of a guide shaft 16' that fits loosely in the hole 14, and the valve body 16'', which is seated on the upper surface of the raised portion 13, has a
A recess 17 is provided to change the direction of incoming air toward the molding space 41, and the air guiding action of the recess 17 causes the valve to open and supply air to the molding surface 31' of the lower mold 31.

The compressed air supply means 4 of the medium size 21 is
The hole 9 opened in each wall part constituting the and the hole 9
and an air supply hose 10 connected to a compressed air supply device (not shown), the hose 1
0 is the molding material poured into the molding space 41.
A check valve 12 is provided to prevent backflow of a ₂ '.

The vibration table 51 is a truck equipped with a vibrator, and is used as an apparatus for manufacturing the FRP molded product A by clamping the flanges 31-1, 21-1 of the lower mold 31 and the middle mold 21 together with the upper base plate 51' with the clamp 18. 100.

In addition, 20 is a weight, and 22 is a guide for demolding.

Γ 1st process In this process, a transparent layer a ₁ is applied to the molding surface 31' of the lower mold 31, and after the transparent layer 11 is cured, the molding space 41 is filled with the upper mold 11 in an open state.
After evenly pouring the molding material a ₂ ', which is mainly composed of unsaturated polyester resin and mixed with a small amount of white pigment, the upper mold 11 is fitted. In this embodiment, the molding material a ₂ ' is first poured evenly into the molding space 41 between the middle mold 21 and the lower mold 31 to remove air, and then the lower mold 31 corresponding to the upper mold 11 is molded. A block of molding material a ₂ ' is placed on the surface 31' and the upper mold 11 is molded together.

The transparent layer _a2 is made of a transparent unsaturated polyester resin to which certain curing agents, accelerators, etc. are added.

The molding material A ₂ ' becomes the intermediate layer A ₂ , and is made of an unsaturated polyester resin, an antifoaming agent, a filler (glass powder), a hardening agent, and a white pigment of 0.015 to 100 parts per 100 parts of the unsaturated polyester resin. Adjusted at a rate of 0.025 parts.

The white pigment is used to give brightness; if it is less than 0.015 part, the color of the back layer _A3 that is formed in the subsequent process will become black and muddy, and if it is more than 0.025 part, the color of the back layer _A3 will be cloudy. Colors do not pass through.

The molding material _a2 ' of this example contains 100 parts of unsaturated polyester resin, 0.1 part of antifoaming agent, and 0.02 part of accelerator.
parts, 230 parts of filler, 1 part of hardening agent, 0.02 parts of white pigment
Adjustments are made by adding each section.

Γ2nd process In this process, the vibration table 51 is vibrated for a predetermined period of time to remove the mixed air and excess molding material a ₂ ′.
The air is discharged from the air vent hole 2.

Since air is mixed in when the molding material a ₂ ' is poured, the vibrating table 51 is vibrated for about 5 minutes to vent the air and discharge excess molding material a ₂ ' from the air vent hole 2 of the upper mold 11.

Γ Third step In this step, after natural hardening, the middle mold 21 and the upper mold 11 are lifted up while pumping air to the molding surface 21' of the middle mold 21, and the middle mold 21 and the upper mold 1 are lifted up.
1 is removed from the lower mold 31 that is in close contact with the molded body A'.

Leave it for about an hour to harden naturally, then
When the clamp 18 is released and the bolt 3 serving as the mold lifting means is artificially rotated to apply demolding force to the middle mold 21, the compressed air supply means 4 supplies the molding surface 21' of the middle mold 21, the upper mold 11, 11', compressed air is fed under pressure to release the molded body A' from the molding surfaces 21', 11'. Thereafter, both the middle mold 21 and the upper mold 11 are removed from the mold using a lifting device (not shown).

Γ 4th process In this process, a back layer _A3 in which glass fibers are impregnated with an unsaturated polyester resin, a curing agent, an accelerator, a polymerization inhibitor, and a color pigment is applied to the molded body.
It is to apply it to A′.

Back layer _A3 is made of a resin composition prepared by adding 1 part of a curing agent, 0.3 parts of an accelerator, a small amount of a polymerization inhibitor, and 10 parts of a coloring pigment to 100 parts of an unsaturated polyester resin. It is impregnated with fibers, and after the bathtub leg 19 is placed on the bottom of the molded body A', it is applied as a lining to the outer surface of the molded body A', including the bathtub leg 19.

Γ5th process In this process, after the back layer a ₃ is cured, the lower mold 31
Air is forced into the molding surface 31' of the FRP molded product A.
It is to remove the mold.

The back layer _a3 hardens in about 3 to 4 hours. After that, the compressed air supply means 5 is operated to forcefully feed air to the molding surface 31' of the lower mold 31, and the FRP
Demold molded product A (bathtub).

[Brief explanation of drawings]

The drawings show an example of the method and apparatus for producing FRP molded products of the present invention, with Figure 1 being a longitudinal cross-sectional view of the manufacturing equipment, and Figure 2 showing the molding material poured into the molding spaces of the lower and upper molds. The vertical cross-sectional view, Figure 3, shows the condition.
FIG. 4 is a partially cutaway vertical cross-sectional view showing a lump of molding material placed on the part corresponding to the upper mold of the lower mold, and FIG. 5 is a vertical cross-sectional view showing the state of natural hardening. FIG. 6 is a partial enlarged cross-sectional view of the main parts showing a state in which the lifting means is rotated and air is pumped by the compressed air supply means; FIG. Fig. 7 is a longitudinal cross-sectional view showing a state in which a back layer is applied to a molded body, and Fig. 8 is a partial enlarged longitudinal cross-sectional view of a main part showing a state in which air is fed under pressure from a compressed air supply means for the lower mold. , FIG. 9 is a longitudinal sectional view showing the demolded state of the FRP molded product. In the figure, 1: mold, 11, 21, 31: upper mold, middle mold, lower mold, 2: air vent hole, _a2 ': molding material, 41: molding space, 51: vibration table, 11',
21', 31': Molded surface, A: FRP molded product, 3:
Mold lifting means, 100: manufacturing device, 4, 5: compressed air supply means, A': molded body, _a1 : transparent layer, _a2 : intermediate layer, _a3 : back layer.

Claims (1)

[Claims] 1 (a) A transparent layer is applied to the molding surface of the lower mold of a mold consisting of three molds that can be matched, consisting of a middle mold, a lower mold, and an upper mold having air vent holes. After curing, a step of mold matching the middle mold to form an intermediate layer in the molding space is poured, and a step of mold matching the upper mold, (b) vibrating a vibration table on which the mold is installed for a predetermined time, (c) After natural curing, lifting up the middle mold and the upper mold while pumping air to the molding surface of the middle mold, and removing the middle mold and the upper mold. (d) applying resin-impregnated glass fibers to the molded body; (e) after the glass fibers have hardened, removing the mold from the lower mold to which the molded body is in close contact; A method for manufacturing an FRP molded product, characterized by sequentially performing the steps of demolding the FRP molded product by force-feeding air to the molding surface. 2. A mold consisting of three molds that can be matched, consisting of a middle mold, a lower mold, and an upper mold having an air vent hole, a vibration table on which the mold is installed, and a vibration table installed in the middle mold, and a An FRP manufacturing device characterized by comprising: a mold lifter for removing the mold from the lower mold; and a compressed air supply means for pumping air to the molding surface of the lower mold and the molding surface of the middle mold.