JPH08323872A - Manufacturing method of reinforced plastic moldings - Google Patents

Abstract

PURPOSE: To reduce the man-hours for defoaming work and improve productivity upon forming an outermost layer or a backup layer in the case of manufacturing a reinforced plastic molding such as a waterproof pan. CONSTITUTION: Gel coat resin is sprayed against the surface of a molding die to cure and form a gel coat layer 21 and, thereafter, reinforcing fibers are sprayed together with thermosetting resin while cutting them into the length of 2-10mm to laminate and form a short fiber reinforced layer 22. Next, reinforcing fibers are sprayed together with the thermosetting resin while cutting them into the length of 25-50mm to laminate them and form a long fiber reinforced layer 23. Further, reinforcing fibers are sprayed together with the thermosetting resin while cutting them into the length of 3-9mm to laminate them and form a short fiber backup layer 26.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a reinforced plastic molded product such as a bathtub or a waterproof pan.

[0002]

2. Description of the Related Art Conventionally, bathroom units have been installed in apartment houses and the like. As shown in FIG. 5, this bathroom unit 1 is provided with a waterproof pan 2 having a washing space formed by FRP molding, a bathtub 3 which is integral with or separate from the waterproof pan 2, and stands on the peripheral edge of the waterproof pan 2. The wall panel 4 is provided and surrounds the waterproof pan 2 and the bathtub 3, and a ceiling panel 5 that covers the upper opening formed by the wall panels 4. The waterproof pan 2 is required to have watertightness and heat resistance, and as shown in FIG. 6, the gel coat layer 21, the short fiber reinforcing layer 22, the long fiber reinforcing layer 23, and the backup layer 24 from the inner surface side. Are laminated in this order (see, for example, JP-A-5-301295).

The short fiber reinforcing layer 22 is formed by cutting reinforcing fibers such as glass fibers and carbon fibers at a length of 2 to 10 mm and spraying them together with a thermosetting resin such as unsaturated polyester resin. No. 23 is a laminate in which the reinforcing fiber is cut at a length of 25 to 50 mm and is sprayed and laminated together with the thermosetting resin. Further, the backup layer 24, which is the outermost layer, is formed by cutting the reinforcing fibers with a length of 25 to 50 mm and spraying them together with the thermosetting resin to be laminated.

A reinforcing frame 25 made of water resistant veneer, synthetic wood, steel or the like may be embedded between the long fiber reinforcing layer 23 and the backup layer 24 in order to improve the strength (see FIG. 7).

[0005]

However, in the production of the reinforced plastic molded product such as the waterproof pan described above, the air and bubbles mixed in the resin material are removed when the backup layer which is the outermost layer is formed ( It has to be defoamed), and a considerable number of man-hours are prepared for the defoaming work, resulting in a problem of reduced productivity.

The present invention has been made in view of the above problems, and is a reinforced plastic molding capable of reducing the number of defoaming steps during the formation of the outermost backup layer and improving the productivity. A method of manufacturing a product is provided.

[0007]

According to the present invention, a gel coat resin is sprayed and cured on the surface of a molding die, and reinforcing fibers are cut with a length of 2 to 10 mm and sprayed together with a thermosetting resin to be laminated. , Reinforced fibers are cut with a length of 25 to 50 mm and sprayed and laminated together with a thermosetting resin,
Further, the present invention is characterized in that reinforcing fibers are interposed or directly cut with a length of 3 to 9 mm while being sprayed and laminated together with a thermosetting resin.

[0008]

[Function] After forming a gel coat layer by spraying a gel coat resin on the surface of the mold to cure it, the reinforcing fibers are added in an amount of 2 to 1
While cutting with a length of 0 mm, it is sprayed and laminated with a thermosetting resin to form a short fiber reinforcing layer. Next, the reinforcing fibers are cut into a length of 25 to 50 mm and sprayed and laminated together with the thermosetting resin to form a long fiber reinforcing layer. Further, a short fiber backup layer is formed by interposing a reinforcing frame on the long fiber reinforcing layer or by directly laminating the reinforcing fibers on the long fiber reinforcing layer with a length of 3 to 9 mm and spraying them together with a thermosetting resin. .

As a result, defoaming work is almost unnecessary when forming the short fiber backup layer, and the productivity can be improved.

[0010]

Embodiments of the present invention will be described below with reference to the drawings.

FIG. 1 shows a waterproof pan 2 which is a reinforced plastic molded product of the present invention.
Is the gel coat layer 21 and the short fiber reinforcing layer 2 from the surface side.
2. Long fiber reinforcing layer 23 and short fiber backup layer 26
Are sequentially laminated.

The gel coat layer 21 is formed of a gel coat resin, for example, an unsaturated polyester resin. The short fiber reinforcing layer 22 reinforces the gel coat layer 21, and a thermosetting resin such as unsaturated polyester resin is mixed and dispersed with reinforcing fibers cut into a length of 2 to 10 mm, such as glass fibers. Has been formed. Similarly, the long fiber reinforcing layer 23 is formed by mixing and dispersing a reinforcing fiber, for example, a glass fiber, which is cut into a length of 25 to 50 mm in a thermosetting resin, for example, an unsaturated polyester resin. Further, the short fiber backup layer 26 is similarly made of a thermosetting resin, for example, an unsaturated polyester resin with 3 to 9%.
It is formed by mixing and dispersing reinforcing fibers cut into a length of mm, for example, glass fibers.

Here, as the thermosetting resin, phenol, vinyl ester, etc. can be used in addition to the unsaturated polyester resin. As the reinforcing fiber, a material having heat resistance and hot water resistance such as polyester, polyamide, polyolefin, polyvinyl alcohol, etc. is used in addition to the glass fiber.

Next, a specific method of manufacturing such a waterproof pan 2 will be described. First, an unsaturated polyester resin is sprayed onto the mold K of the waterproof pan 2 to cure it, thereby forming the gel coat layer 21 (FIG. 2). Next, the length of the glass fiber 22x is 2 to 10 m by the roller cutter R.
The unsaturated polyester resin 22a is atomized from the spray nozzle S at the same time as being blown while being cut into m, whereby the short glass fibers 22b and the unsaturated polyester resin 22a are associated with each other in the air, and the gel coat layer 21 is mixed. And spray to stack (see FIG. 2). As a result, the unsaturated polyester resin 22a and the glass short fibers 22
With b, the short fiber reinforcing layer 22 for reinforcing the gel coat layer 21 is formed (see FIG. 3).

Then, the glass fiber 23x is blown out while being cut into a length of 25 to 50 mm by the roller cutter R, and at the same time, the unsaturated polyester resin 23a is sprayed from the spray nozzle S in the form of mist so that the glass fiber 23x and The saturated polyester resin 23a is associated in the air, and is sprayed on the short fiber reinforcing layer 22 while being mixed and laminated (see FIG. 3). As a result, a long fiber reinforcing layer 23 for reinforcing the short fiber reinforcing layer 22 is formed by the unsaturated polyester resin 23a and the glass short fibers 23b (FIG. 4).
reference).

Thereafter, the glass fiber 26x is blown out while being cut into a length of 3 to 9 mm by the roller cutter R, and at the same time, the unsaturated polyester resin 26a is sprayed from the spray nozzle S in the form of mist, whereby the short glass fiber 26
b and the unsaturated polyester resin 26a are associated with each other in the air, and while being mixed, they are sprayed on the long fiber reinforcing layer 23 and laminated (see FIG. 4). As a result, the short fiber backup layer 26 is formed by the unsaturated polyester resin 26a and the glass short fibers 26b (see FIG. 1).

In this case, the viscosity and thixotropy of the unsaturated polyester resin 26a forming the short fiber backup layer 26 are the same as those of the unsaturated polyester resins 22a and 23a forming the short fiber reinforcing layer 22 and the long fiber reinforcing layer 23. And the numerical value is raised compared with the rocking degree. Specifically, the viscosity of the unsaturated polyester resins 22a and 23a in the short fiber reinforcing layer 22 and the long fiber reinforcing layer 23 is 2.9 to 4.0 poise,
Whereas the thixotropic degree is 2.0 to 3.9, the viscosity and the thixotropic degree of the unsaturated polyester resin 26a in the short fiber backup layer 26 are 8.0 to 15.
It has 0 poise and 3.8 to 5.0, and is more tenacious and has a property that it does not easily sag.

In the short fiber backup layer 26 formed as described above, only fine harmless fine bubbles are generated, and the defoaming work is unnecessary except for the corner portions.
For example, in the conventional formation of the backup layer, three workers required a defoaming work of 1 minute and 30 seconds per person, whereas in this embodiment, one worker took 1 minute 35 seconds. The defoaming work in seconds is sufficient, and the total man-hour can be reduced to 1/3 of the conventional one.

In this embodiment, the waterproof pan 2 having the gel coat layer 21, the short fiber reinforcing layer 22, the long fiber reinforcing layer 23, and the short fiber backup layer 26 formed in this order is exemplified, but the waterproof pan 2 is limited. Not FR, other FR
It can also be applied to P products, such as bathtubs and containers. Further, in such an FRP product, when particularly strong strength is required, a reinforcing frame such as a water resistant veneer or a steel material can be interposed between the long fiber reinforcing layer 23 and the short fiber backup layer 26.

[0020]

As described above, according to the present invention, after the gel coat resin is sprayed and cured on the surface of the mold, the reinforcing fibers are cut into 2 to 10 mm lengths and sprayed together with the thermosetting resin to be laminated. Then, the reinforcing fiber is 25 to 50 m.
By cutting and cutting with m length and spraying together with thermosetting resin, and further by interposing a reinforcing frame or directly cutting reinforcing fiber with 3-9 mm length and spraying with thermosetting resin, Since the defoaming work is almost unnecessary when forming the short fiber backup layer which is the outermost layer, it is possible to greatly improve the productivity in manufacturing the FRP product.

[Brief description of drawings]

FIG. 1 is a cross-sectional view showing a waterproof pan molded by a method for manufacturing a reinforced plastic molded product of the present invention with a part of the waterproof pan omitted.

FIG. 2 is an explanatory view showing a forming process of the waterproof pan of FIG.

FIG. 3 is an explanatory view showing a forming process of the waterproof pan of FIG.

FIG. 4 is an explanatory view showing a forming process of the waterproof pan of FIG.

FIG. 5 is a perspective view showing a bathroom unit with a part thereof omitted.

FIG. 6 is a sectional view showing a conventional waterproof pan with a part thereof omitted.

FIG. 7 is a sectional view showing another embodiment of the conventional waterproof pan with a part thereof omitted.

[Explanation of symbols]

 1 Bathroom Unit 2 Waterproof Pan 21 Gel Coat Layer 22 Short Fiber Reinforcement Layer 22a Thermosetting Resin 22b Reinforcing Short Fiber (Glass Short Fiber) 23 Long Fiber Reinforcing Layer 23a Thermosetting Resin 23b Reinforcing Long Fiber (Glass Long Fiber) 26 Short Fiber Backup layer 26a Thermosetting resin 26b Reinforcing short fiber (glass short fiber)

Claims (1)

[Claims] 1. A gel coat resin is sprayed and cured on the surface of a molding die, and reinforcing fibers are cut with a length of 2 to 10 mm and sprayed together with a thermosetting resin to be laminated, and then,
Reinforcing fibers are cut with a length of 25 to 50 mm and sprayed with a thermosetting resin to be laminated, and further, with a reinforcing frame interposed or directly, reinforcing fibers are blown with a thermosetting resin while being cut with a length of 3 to 9 mm. A method for producing a reinforced plastic molded article, which comprises laminating the layers together.