JPH0725097B2 - FRP molding method - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION (Industrial field of application) The present invention relates to press molding (compression molding) of a multicolored or patterned patterned molded body made of FRP (glass fiber reinforced plastic).
Regarding the manufacturing method by the law, especially the manufacturing method of beautiful FRP molded products with multicolored or patterned borders of different colors such as waterproof boards, bathtubs, bathtubs with wash basins (half unit) etc. Regarding

(Prior art and its problems) Conventionally, large moldings such as glass fiber reinforced plastic (called FRP) bathroom half units are mainly molded by hand-up, spray-up, or resin injection molding. Recently, some mass production is being attempted by the press molding method. However, in this case, at present, only the same monochromatic molded product can be molded. In the case of a press-molded product, it is a mono-colored molded product even though the quality and physical properties of the molded product are constant and overall high quality, so it is regarded as cheap like a general-purpose plastic and treated as a low-cost product. It is general, and high-quality products with multicolor or patterned are desired.

In the conventional hand-up and spray-up molding methods,
Although bathroom half units with multiple colors or patterns have been obtained, the press molding method has only small molded products such as trays for food service industry, tableware, etc., width 1,000 ~ 1,300 mm, length 1,40
It is not known that large moldings such as bathroom half units of 0 to 1,800 mm and height of 500 to 800 mm are multicolored and patterned.

The two-color molding method by press molding is often test-molded on medium-sized products such as chairs, but this is also a miscellaneous goods such as chairs because the ridge lines (borders of different colors) of the coloring part collapse and are not clear. Even if it could be applied to products, it was difficult to use it for the production of high-grade FRP molded products such as bathroom half units, which require interior properties by the molding method as it is.

(Means for Solving Problems) The inventors of the present invention have solved these problems and have a high quality comprehensively by using a press molding method for multicoloring of a large-sized pressed body, and designing with a pattern design. As a result of earnest research on the specific FRP pre-colored or molded with a patterned pattern on the mold surface corresponding to the colored part of the molded body such as the floor surface of the bathroom half unit and the bathtub inner surface Set a decorative sheet molding product, and charge it with a molding material <sheet mold compound (hereinafter referred to as SMC) or bulk mold compound (hereinafter referred to as BMC)>, which has a different color from the decorative sheet molded product, and heats it. FR such as bathroom half unit, which has high quality and is excellent in design and fashion, which is integrated with the veneer molded product by pressure and compression molding.
The present invention has been completed by finding a manufacturing method of a P-molded body by a press molding method.

That is, the present invention provides a method for producing a multicolored or patterned patterned FRP molded article using a FRP decorative sheet molded article and a molding material, wherein the FRP decorative sheet molded article has The thickness of the part is 1/2 or less of the thickness of the central part of the decorative sheet molded product, and / or all the end parts have an inclination of 80 degrees or less.

(2) Flexural modulus of 50-500k at ambient temperature of 120-150 ℃
It is g / mm ² .

It is intended to provide a method for producing a multicolored or patterned FRP molded article which satisfies the above conditions.

(Structure) In the manufacturing method of the present invention, a preformed FRP decorative sheet molded product (referred to as a decorative sheet molded product) is first used. The decorative sheet molded product is (1) as shown in FIG. Is the thickness (t) 1/2 or less of the thickness (T) of the center part of the decorative sheet molded product (first
(See FIGS. (A) and (b)) and / or the end portion of which has an inclination (θ) of 80 degrees or less (FIGS. 1 (a), (b),
(See (c)). More preferably, θ is 45 degrees or less.

If this condition is not satisfied, it will be difficult to obtain a beautiful molded product in which the colored portion (border between colors) is clear. Ideally, it is easier for the decorative sheet molded product 1 to become closer to the mold due to the flow pressure of the molding material 2 if it is thinner toward the end as shown in FIG. It is difficult to obtain a molded product. Therefore, industrially, the end portion thickness (t) of the decorative sheet molded product 1 as shown in FIGS.
Is less than 1/2 of the central thickness (T), and its inclination angle (θ)
By using the decorative sheet molded product 1 having an angle of 80 degrees or less, a molded product with a clean ridge can be obtained. That is, the decorative plate molded product 1
Is a multi-colored or patterned bathroom half unit, etc. that is made by stacking and encasing patterned non-woven fabrics or by molding with a molding material of a different color tone from the main body molded product such as a bathroom half unit. It is possible to integrally mold a large-sized molded body of (1) by a press molding method.

Further, the decorative board molded product of the present invention has a flexural modulus of 50 to 500 kg / mm ² at an ambient temperature of 120 to 150 ° C. as the condition (2). Only with the condition (1), the multicoloring and patterning due to the beautiful ridgeline of the present invention are insufficient. In the mold temperature ambient temperature of 120 to 150 ° C. at the time of the press molding, the decorative plate flexural modulus molded article 1 tends warp greater than 500 kg / mm ^2, and 50 kg / mm ² smaller than in Matagyaku molding material A flow pressure of 2 may cause cracking or cutting, which is not preferable. Particularly preferably, it is 100 to 450 kg / mm ² .

If the decorative sheet molded product 1 having a flexural modulus in this range (50 to 500 kg / mm ² ) is used, a good product ratio of about 80% can be obtained without taking the shape of the condition (1), but 100%. In order to obtain a non-defective product rate, it is necessary to take the shape of the broken part under the condition (1).

Decorative plate molded products are flat or curved plates with a thickness of about 1 to 10 mm,
It has a different color tone from the molding material, such as a hemispherical plate, and has a different color tone, and has a multicolored, patterned surface.The shape is round, square, triangular, trapezoidal, ellipse,
Any shape may be used as long as the above conditions (1) and (2) such as a diamond shape, a star shape, and a design shape are satisfied. In addition, this decorative board molded product is a resin compound prepared by mixing thermosetting resin such as unsaturated polyester resin, epoxy resin, vinyl ester resin, colorant, filler, catalyst and other additives with glass fiber or the like. Infiltrate the textile material of 80-160
It is obtained by molding by a press molding method or a hand lay-up method under the conditions of ℃ and 10 to 100 kg / cm ² .

The decorative plate molded product is placed under the molding material and press-molded. This molding material is a resin compound in which a thermosetting resin such as an unsaturated polyester resin, an epoxy resin, or a vinyl ester resin is mixed with a filler, a catalyst and other additives, and a glass fiber (chop strand) is formed into a sheet. It is an impregnated sheet mold compound (SMC) or a bulk mold compound (BMC) obtained by kneading glass fibers (chop strands) with a kneader or the like. Further, this material has a color tone different from that of the decorative board molded product.

The FRP molded body of the present invention is manufactured by press molding using these materials, and the molding conditions at that time are a temperature of 100 to 160 ° C. and a pressure of 30 to 150 kg / cm ² .

Next, the manufacturing of the bathroom (half unit) will be specifically described with reference to the drawings.

As shown in FIG. 4, the preformed decorative sheet molded article 1 of the present invention is set on the mold 3 of the bathroom half unit,
The molding material 2 is placed on it and press-molded under the above-mentioned molding conditions to produce a multicolored or patterned patterned FRP molded body with a beautiful colored portion.

Next, the conventional decorative plate molded product 1'shown in FIG. 2 is set on the mold 3 of the bathroom half unit, and the molding material 2 is placed thereon.
The ambient temperature is 120
Due to the large bending elastic modulus of up to 150 ° C, the decorative sheet molded product is turned upside down, and the material flows between the pre-formed decorative sheet molded product 1 and the mold 3 to form a ridge line (a boundary line). If it sticks or fogging occurs on the decorative plate molded product 1 due to the molding material, the commercial value of the molded product is significantly reduced.

According to the present invention, it is possible to obtain a high-quality large-sized FRP molded product having a multicolored and patterned pattern, which is excellent in designability and fashionability because a beautiful color difference part can be formed.

Therefore, multicolored bathroom waterproof pans, bathtubs, bathtubs with washrooms,
It is suitable for manufacturing FRP molded products with patterned patterns.

Next, description will be given based on examples, but "%" and "parts" in the text are based on weight.

[Example-1] In order to obtain a press-molded body of a bathroom half unit in which the floor surface of the washroom is patterned, first, the FRP decorative board molded product 1 is molded by the hand-reup molding method.

Generally, a non-slip pattern is often put on the floor of a bathroom to prevent people from slipping when taking a bath. This time, in order to insert the uneven pattern of the non-slip pattern, which is the rough pattern called the glass plate, the flat plate steel plate is used for the hand-reup molding with the same non-slip pattern and size as the floor surface of the washing mold of the bathroom half unit press mold. Created.

First, in order to mold a decorative sheet molded product by the hand-up molding method, RS-305 (a mold releasing agent manufactured by Dainippon Ink and Chemicals, Inc.) is applied to the above mold with a sponge. After the release agent was dried, 100 parts of a resin prepared by mixing 50 parts of Polylite GC-230 (manufactured by Dainippon Ink and Chemicals, Inc.) as unsaturated polyester resin with 50 parts of Polylight FG208 (manufactured by Dainippon Ink and Chemicals, Inc.) Using a resin composition containing 1.0% of RP-126 (manufactured by Dainippon Ink and Chemicals, Inc.) as a promoter and 1.2% of methyl ethyl ketone peroxide as a curing agent, one surfacing mat 30 g / m ² was laminated. Next, put 10 g / m ² polyester non-woven fabric with an abstract pattern printed on it, then stack 1 sheet of 265 g / m ² chopped strand mat, degas sufficiently, and leave it in a curing oven at an ambient temperature of 60 ° C for 2 hours. After that, the mold was released from the mold. After that, it was left in a curing oven at an ambient temperature of 100 ° C. for 2 hours to sufficiently perform post-curing to obtain a decorative sheet molded product 1 having an edge portion as shown in FIG. 3 and having a plate thickness of about 1.2 mm. Cut this to the specified size where you want to design the pattern on the floor of the washroom, and as shown in Fig. 3, the edge thickness of the molded product is
A taper cut with a width of about 5 mm and a thickness of 1.2 mm at the center was made to 0.5 mm. The inclination angle (θ) of the end portion at that time is about 8 °, and the bending elastic modulus of this decorative board molded product is
It was 350 kg / mm ² at an ambient temperature of 140 ° C.

Next, the convex mold 3 of the press mold of the bathroom half unit
After adjusting the temperature of the concave mold 4 to 140 ° C and the temperature of the concave mold 4 to 125 ° C, set the decorative plate molded product 1 having the end portion of Fig. 3 created above on the convex mold surface of the wash floor, and use it as the SMC molding material 2. Dick Matt 2463-i (manufactured by Dainippon Ink and Chemicals, Inc.) was charged as shown in FIG. 4 and pressure-molded at a molding pressure of 70 kg / cm ² for 6 minutes. After that, by opening the mold and releasing the press-molded product from the mold, the washing room floor without the ridgeline of the integrated fusion part of the decorative plate molded product and the molding material has an abstract pattern and overflows with a high-class feeling. We obtained a press-molded body of a bathroom half unit with high design and fashion.

[Comparative Example 1] When molding the above-mentioned FRP decorative board molded product, polylite was used as a general hard type unsaturated polyester resin.
The same glass as in Example 1 was prepared by using a resin composition in which RP-126 as an accelerator was added to 1.0 part of 100 parts of FG-284 (manufactured by Dainippon Ink and Chemicals, Inc.) and 1.2% of methyl ethyl ketone peroxide was used as a curing agent. After laminating with the composition (1 piece of 30g / m ^{2 surface} mat + 10g / m ² non-woven fabric + 1 piece of 265g / m ² chop strand mat), after curing and post-curing under the same conditions, end treatment as shown in FIG. went. The flexural modulus of this decorative sheet molded product was 750 kg / mm ² at an ambient temperature of 140 ° C. Using this decorative sheet molded product 1 ′, an SMC molding material was charged under the same conditions as in Example-1 and heating and pressure molding were carried out. However, as shown in FIG. 2, the SMC molding material flowed between the pattern-patterned decorative plate molded article and the mold surface, and a fog phenomenon occurred, so that a good product could not be obtained.

[Example-2] Since a non-slip pattern on the floor of the washroom was molded using a bathroom half unit mold in which tile patterns were engraved, a flat plate mold for forming a decorative plate having the same pattern as the floor of the washroom was prepared. This mold has an SMC with a brownish tone.
DAIKMAT 6020B (manufactured by Dainippon Ink & Chemicals, Inc.) is charged as a molding material, and the mold temperature is concave, 4130 ° C, convex.
It was pressed and molded under the conditions of 3140 ° C., molding pressure of 50 kg / cm ² , and pressure time of 2 minutes. In addition, Dick mat molded under these conditions
The flexural modulus of the molded product using 6020B is 140 ℃ at ambient temperature.
It was 180 to 200 kg / mm ² . Further, as shown in FIG. 6 (a), the decorative plate molded product 1-a molded by using this mold has an edge thickness (t) of 0.3 mm with a circumference of 3 mm and a width of about 10 mm from this. The maximum thickness (T) of the molded product (T) was increased to 1.5 mm while gradually tapering. In this case, the inclination angle (θ) of the end portion was about 7 °.

Furthermore, using a separate flat plate mold to mold the bathroom bottom decorative plate molded product 1-b, a flat plate with a thickness (T) of 1.5 mm is molded under the same molding conditions as above, using the same SMC molding material (Dick Mat 6020B). did. Cut this flat plate into the shape of the bottom of the bath
As shown in Figure (b), the end structure has a tip thickness (t) of 0.5 m.
It was 6 m wide, and the taper cut was done at an angle (θ) of about 10 ° and the backside sanding treatment was finished.

Next, as shown in FIG. 7, the decorative plate molded products 1-a and 1-b shown in FIG. 6 were adjusted to a mold temperature of 140 ° C. for the convex mold 3 (lower mold) and 125 ° C. for the concave mold 4 (upper mold). Place the decorative plate molded product 1-a on the floor surface of the warm bathroom half unit mold and the decorative plate molded product 1-b on the bathtub floor surface.
Dick Mat 2463-i2 was charged as an SMC molding material, and a bathroom half unit was molded under the conditions of a molding pressure of 70 kg / cm ² and a pressing time of 6.0 minutes. In this case, Dick Mat 24
63i has an ivory color tone, and the decorative sheet molded product has a brown color tone, so the bottom of the bathtub and the floor of the washroom have a different color tone from other parts, which creates a sense of luxury, fashion, and
A bathroom half unit molded body was obtained by multicolor molding excellent in design.

[Brief description of drawings]

FIG. 1 (c) is an ideal end cross-sectional structural view of a decorative sheet molded product according to the present invention. (B), (a) is a cross-sectional structural view of a practical end portion of a decorative board molded product according to the present invention. FIG. 2 (a) is a sectional view of the bathtub molding performed by the method prior to the present invention, in which 1'is a decorative sheet molded product to which the invention of the present invention is not applied, and 2 is an SMC molding material. 2 (b) is a detailed view of part (a) of FIG. 2 (a). Since the decorative plate molded product is reversely slanted, the molding material 2 has a mold 6 and a decorative plate molded product 1 '. It shows the inflow between. FIG. 3 is a sectional structure view of an end portion of the decorative sheet molded product 1 in Example-1. FIG. 4 is a cross-sectional view of the bathroom half unit molding in Example-1, in which the washing scene side is multicolor molded. FIG. 5 is a sectional structure view of an end portion of a decorative plate molded product 1'before the present invention, and FIG. 6 (a) is an end sectional structure view of a decorative plate molded product 1-a for a wash floor in Example-2. Indicates. (B) is a decorative plate molded product 1 for the bottom of the bath in Example-2
-B shows an end cross-sectional structural diagram of FIG. FIG. 7 is a cross-sectional view of the bathroom half unit molding according to the present invention based on Example-2, in which multicolor molding of the floor surface of the washroom and the bottom surface of the bathtub is carried out. 1 ... Veneered product of the present invention, 1-a ... Veneered product used for the wash floor of Example-2, 1-b ... Example-2
Decorative plate molded product used on the bottom of the bathtub of 1 '... Conventional decorative plate molded product, 2 ... Molding material, 3 ... Convex mold, 4 ... Concave mold.

Claims (1)

[Claims] 1. A method for producing a multicolored or patterned patterned FRP molded article using a FRP decorative sheet molded article and a molding material, wherein the FRP decorative sheet molded article comprises (1) The thickness depends on the thickness of the central part of the decorative sheet molded product.
It is 1/2 or less, and / or all the edges have an inclination of 80 degrees or less. (2) Flexural modulus of 50-500k at ambient temperature of 120-150 ℃
It is g / mm ² . A method for producing a multicolored or patterned FRP molded product, which satisfies the above conditions.