JP3247541B2 - Manufacturing method of FRP molded product and FRP molded product - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION The present invention relates to a method of integrally molding a preformed pattern sheet and a press molding material such as a sheet molding compound (hereinafter, referred to as SMC), a bulk molding compound (hereinafter, referred to as BMC), or the like. The present invention relates to a method for producing an obtained FRP molded product having a pattern on its surface and an FRP molded product.

[0002]

2. Description of the Related Art A method of forming a pattern on the surface of an FRP molded product is disclosed in JP-A-4-341809 and JP-A-63-57.
No. 210, etc., a thermosetting resin composition is applied to a pre-patterned film, and after semi-curing, the film is peeled off to transfer the pattern to the semi-cured sheet.
Get the door, or to obtain a molded prepreg sheet with thermosetting resin composition and the printing paper such as fiber material, placing the press-molding material on placing the prepreg sheet having the pattern on the mold There is a method of forming a FRP molded article with a pattern by heating and pressurizing the molded article with a press.

[0003]

However, a pattern sheet into which a non-woven fabric is inserted or a pattern sheet comprising only a thermosetting resin layer is formed integrally with a press molding material by heat and pressure molding. Due to deformation, cracks may occur along the irregularities, or the press-formed material may be broken by being pressurized and flowing.
There is a problem that the commercial value of the RP molded product is lost. In addition, as in the present case, an F type using a molding die designed to impart irregularities to the surface of the molded product and enhance high designability and high-grade appearance.
In RP molding, cracks tend to occur on the pattern surface, and in this regard, it is necessary to provide a molding method that is unlikely to cause problems. SUMMARY OF THE INVENTION The present invention has been made in view of the above-mentioned prior art, and its purpose is to accurately provide a target pattern at a designated position on an FRP surface. To reduce the rate.
The present invention relates to a prepreg sheet with a pattern or semi-cured
An FRP molded product that is formed by pressing or bonding an organic fiber base material to one side of the sheet and forming it together with the press molding material to prevent cracking and destruction of the pattern surface that occurs when curing and patterning are performed simultaneously. And a method for producing the same.

[0004]

SUMMARY OF THE INVENTION According to the present invention, a pattern sheet in which an organic fiber base material is adhered or pressure-bonded to one side of a preformed sheet is used to withstand a load generated when integrally formed with a press-formed material and to reinforce the sheet. Has the function of improving the ability to follow the irregularities on the surface of the mold, preventing cracks and breakage of the pattern sheet, and preventing bubbles and swelling generated at the interface between the pattern sheet and the press molding material. The present invention provides a prepreg sheet or a semi-finished
An organic fiber substrate is pressed or adhered to one side of the cured sheet , a press molding material is placed on the organic fiber substrate side, and heated and pressed to form an FRP molded product. It relates to an FRP molded product.

[0005] While not limited to a prepreg sheet or semi-cured sheet and its those sheets of preparation was subjected to pattern patterns used in the present invention, for example, the decorative paper pattern pattern is printed, the thermosetting resin composition Pre -impregnated and semi-cured
A thermosetting resin composition 2 containing a thermosetting resin and an organic peroxide is placed on a prepreg sheet or a patterned semi-cured sheet made as shown in FIG. 1, that is, a polyester base film 1, and a pattern is formed on the surface thereof. A transfer film 4 having a base film 1 and a transfer film 4 is pressed and stretched in one direction by a roller 5 or the like, heated and semi-cured, and the base film 1 and the transfer film 4 are peeled off. A cured sheet or the like is used. Prepreg sheet or one side of a semi-cured sheet was given the thus obtained pattern pattern, preprocessor
In the case of a leg sheet, the surface where the pattern is not printed, FIG.
In the case of a semi-cured sheet with a pattern shown in (1), an organic fiber base material is pressure-bonded to the transfer surface of the pattern or adhered by a polyester primer or the like.

In the present invention, an organic fiber base material is used, but an inorganic fiber base material is not used because irregularities along fibers are formed on the surface of the FRP molded product. As the organic fiber base material used in the present invention, polyester nonwoven fabric or woven fabric, acrylic nonwoven fabric or woven fabric, papers and the like are used.
These substrates are made of the above-mentioned prepreg sheet or semi-cured sheet.
Pressed or bonded to one side of the sheet .

Also, a prepreg sheet with a pattern or
As a thermosetting resin composition used for producing a semi-cured sheet, a resin composition containing an unsaturated polyester resin, an acrylic resin, a vinyl ester resin, or the like is used. These resins are used in combination with diallyl phthalate, a prepolymer thereof, or the like to form a prepreg sheet or a semi-finished prepreg sheet.
It is a cured sheet . Organic peroxides used to cure these thermosetting resin compositions include peroxy ketals, dialkyl peroxides, diacyl peroxides, and peroxy esters.

[0008] Prepreg sheet or semi-rigid with a pattern
Sheet 6 is cut to a desired size, and as shown in FIG.
8, placed at a predetermined position on the lower mold 9 coated with a release agent so as to be on the side of a press molding material such as BMC, heated and pressed, and the sheet is cured simultaneously with the curing of the molding material; An FRP molded product having a pattern on the surface can be obtained by bonding and integrating with a press molding material. In FIG. 2, reference numeral 10 denotes an upper mold.

[0009]

Next, examples of the present invention will be described. Example 1 50 parts by weight of polyset TH2800 (trade name of an unsaturated polyester solution, manufactured by Hitachi Chemical Co., Ltd.), 15 parts by weight of diallyl phthalate, diallyl phthalate prepolymer on decorative paper (80 g / m ² ) on which a pattern was printed A prepreg sheet impregnated with a resin composition consisting of 5 parts by weight (trade name, manufactured by Osaka Soda Co., Daiso Dup), 30 parts by weight of toluene and 2 parts by weight of benzoyl peroxide, dried at 95 ° C. for 15 minutes, and provided with a pattern. It was created. A polyester nonwoven fabric having a basis weight of 45 g / m ² (manufactured by Unitika Ltd., trade name: 20451FLV) is pressure-bonded to this sheet, and the decorative paper is placed on the mold with the pattern surface of the decorative paper facing the mold. Pressing (50 kg / cm ² ) and heating (front mold 150 ° C., back mold 145 ° C.) The pattern sheet was completely cured as the SMC flow-hardened in the mold, and integrated with the SMC to obtain a patterned FRP molded product. The FRP molded product obtained in this way follows the irregularities on the surface of the mold, has no cracks that are likely to occur in the corners of the irregularities, and has a pattern sheet and S
No blistering occurred at the MC interface, and no defect was observed.

Example 2 As shown in FIG. 1, a polyset 37 was attached to one end of the surface of a base film 1 made of a polyester film having a thickness of 50 μm.
15 (trade name of unsaturated polyester resin, manufactured by Hitachi Chemical Co., Ltd.), 100 parts by weight of Parloyl TCP (trade name, manufactured by NOF CORPORATION) as a curing agent and 1.0 part by weight of 4-methyl The thermosetting resin composition 2 to which 0.5 part by weight of -2,4 diphenylpentene-1 (α-methylstyrene dimer) (trade name: NOFMER MSD, manufactured by NOF Corporation) was added was placed in a lump. On the other hand, one side is patterned with an ink soluble in this thermosetting resin composition to form a granite pattern layer 3 having a thickness of 50 μm.
A transfer film 4 made of a polyester film was prepared. The end of the patterning surface of the transfer film 4 is pressed against the block of the thermosetting resin composition 2, and then pressed from above the transfer film 4 from one end of the base film 1 by the roller 5 to form a block of heat. The curable resin composition 2 was uniformly stretched, and the polymerization of the resin proceeded in a curing furnace maintained at 70 ° C. for 60 minutes. The first-stage curing was completed in a state where the polymerization was stopped at a curing degree (reaction rate of styrene monomer) of 80% by the action of the chain transfer agent added earlier. Thereafter, when peeling off the transfer film 4, the semi-curing the pattern layer 3 on the surface of the granite tone thermosetting resin 2 in a semi-cured state is subjected pattern pattern transcribed
Sheet 6 was formed. Then semi-cured with a pattern
A polyester nonwoven fabric having a basis weight of 45 g / m 2 (product name: 20451 FLV) was pressed onto the transfer surface of the pattern layer of the sheet and placed on a mold with the nonwoven fabric side facing upward as shown in FIG. Pile, pressurized (50kg / cm2),
It was molded by heating (150 ° C.). FR thus obtained
The P molded product followed the irregularities on the surface of the mold, did not crack at the corners of the irregularities, and did not recognize any blistering at the interface between the prepreg sheet with the pattern and the SMC.

SMC used in Examples 1 and 2
Is a compound having the composition shown in Table 1 and glass roving cut into 1 inch (trade name: RS460PF- manufactured by Nitto Boseki Co., Ltd.).
750 AS) was prepared by a known method so that the glass content was about 27% by weight.

[0012]

[Table 1]

[0013]

The method for producing an FRP molded product of the present invention is based on SM
As a technique for imparting a sense of quality by patterning the surface of a single-color FRP molded product such as C or BMC, it is effective in preventing various defects and defects that occur when integrally molded with SMC, BMC, or the like. According to the present invention, the degree of freedom with respect to pressure and temperature during press molding is increased, and irregularities on the surface of a molding die can be increased as compared with the prior art, so that it is possible to give a sense of quality.

[Brief description of the drawings]

FIG. 1 is a diagram showing an example of a method for producing a patterned semi-cured sheet used in the present invention.

FIG. 2 is a diagram showing an example of the production method of the present invention.

[Explanation of symbols]

REFERENCE SIGNS LIST 1 polyester base film 2 thermosetting resin composition 3 pattern 4 transfer film 5 roller 6 prepreg sheet or semi-cured sheet provided with pattern 7 organic fiber base material 8 SMC 9 lower mold 10 upper mold

──────────────────────────────────────────────────の Continuing on the front page (51) Int.Cl. ⁷ Identification code FI B29L 9:00 B29C 67/14 G (72) Inventor Yoichi Kuwana 1010 Ippongi, Toyama City, Toyama Prefecture Hitachi Chemical Unit Co., Ltd. (56) References JP-A-6-91837 (JP, A) JP-A-4-341809 (JP, A) JP-A-53-146769 (JP, A) JP-A-47-43164 (JP, A) JP-A-54 -18871 (JP, A) JP-A-5-318469 (JP, A) JP-A-6-134785 (JP, A) (58) Fields investigated (Int. Cl. ⁷ , DB name) B29C 43/18- 43/20 B29C 43/32-43/34 B29C 70/06 B32B 31/04-31/20 B29B 11/14-11/16 B29B 15/08-15/12

Claims (2)

(57) [Claims] 1. A prepreg sheet or half with a pattern
A method for producing an FRP molded product, comprising: pressing and bonding an organic fiber base material to one surface of a cured sheet ; placing a press-formed material on the organic fiber base material side; 2. FRP obtained by the production method according to claim 1.
Molding.