JPH11123735A - Production of fiber reinforced plastic - Google Patents
Production of fiber reinforced plasticInfo
- Publication number
- JPH11123735A JPH11123735A JP9289314A JP28931497A JPH11123735A JP H11123735 A JPH11123735 A JP H11123735A JP 9289314 A JP9289314 A JP 9289314A JP 28931497 A JP28931497 A JP 28931497A JP H11123735 A JPH11123735 A JP H11123735A
- Authority
- JP
- Japan
- Prior art keywords
- nonwoven fabric
- reinforced plastic
- resin
- decorative sheet
- thermosetting resin
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
Links
Landscapes
- Laminated Bodies (AREA)
- Casting Or Compression Moulding Of Plastics Or The Like (AREA)
- Moulding By Coating Moulds (AREA)
Abstract
Description
【０００１】[0001]
【産業上の利用分野】本発明は、家具、厨房器、浴槽、
建築内装材、弱電機器キャビネット等の表面材として好
適に使用される繊維強化プラスチック（ＦＲＰ）の製造
方法に関するものである。The present invention relates to furniture, kitchen appliances, bathtubs,
The present invention relates to a method for producing a fiber reinforced plastic (FRP) suitably used as a surface material for a building interior material, a light electrical equipment cabinet, or the like.
【０００２】[0002]
【従来の技術】従来、この種の繊維強化プラスチックを
製造する方法として、模様付不織布、印刷紙等の化粧シ
ートを熱硬化性樹脂で含浸処理し、これをシートモール
ディングコンパウンド（ＳＭＣ）やバルクモールディン
グコンパウンド（ＢＭＣ）などのＦＲＰ未硬化物と積層
して熱プレスにより一体成形することが一般的に行われ
ている（特開昭４８−１２８７６号公報等参照）。2. Description of the Related Art Conventionally, as a method for producing this kind of fiber-reinforced plastic, a decorative sheet such as a patterned nonwoven fabric or printing paper is impregnated with a thermosetting resin, and this is subjected to sheet molding compound (SMC) or bulk molding. It is common practice to laminate with an uncured FRP such as a compound (BMC) and integrally mold it by hot pressing (see Japanese Patent Application Laid-Open No. 48-12876).
【０００３】[0003]
【発明が解決しようとする課題】従来の技術で述べた製
造方法では、金型内で加熱加圧され軟化したＳＭＣ等が
流動し、剪断力を生じて表面の化粧シートに歪や亀裂が
生じるという問題がある。すなわち、例えば化粧シート
が不織布であると、構成繊維の軟化温度がＳＭＣの成形
温度より低い場合は構成繊維自体が軟化変形し、また構
成繊維の軟化温度がＳＭＣの成形温度より高い場合であ
っても、各構成繊維がＳＭＣと共にずれることによって
変形転移するからである。また、不織布は表面状態が滑
らかでないので鮮明な印刷ができないという問題もあ
る。このような問題を解消するために予め不織布にフィ
ルムをラミネートしておくのがよいと考えられるが、成
形時にＳＭＣ樹脂が不織布の層中に均一に浸透せず接着
性が不安定になり、また不織布の繊維間に残った残留空
気が成形時にエアー噛み不良の要因になるという新たな
問題が発生する。このような残留空気は、層間の接着力
低下につながると共に、ＦＲＰが使用時に加熱された際
に膨張してＦＲＰに膨れ（ブリスター）を生じるため不
都合である。In the manufacturing method described in the prior art, SMC or the like softened by heating and pressurizing in a mold flows and generates a shearing force, thereby causing distortion and cracks in the decorative sheet on the surface. There is a problem. That is, for example, when the decorative sheet is a nonwoven fabric, the constituent fibers themselves soften and deform when the softening temperature of the constituent fibers is lower than the molding temperature of the SMC, and the softening temperature of the constituent fibers is higher than the forming temperature of the SMC. This is because each of the constituent fibers is deformed and displaced by being shifted together with the SMC. Further, there is also a problem that clear printing cannot be performed because the surface state of the nonwoven fabric is not smooth. It is thought that it is better to laminate the film on the non-woven fabric in advance in order to solve such a problem, but the SMC resin does not uniformly penetrate into the non-woven fabric layer at the time of molding and the adhesiveness becomes unstable, and A new problem arises in that residual air remaining between the fibers of the nonwoven fabric causes air entrapment failure during molding. Such residual air is disadvantageous because it leads to a decrease in the adhesive strength between the layers and expands when the FRP is heated during use, causing blisters in the FRP.
【０００４】本発明は、上記のような問題点に鑑みてな
されたものであり、その目的とするところは、化粧シー
トに不織布を使用しながらも、不織布の層間剥離や外観
不良がなく、また加熱時ブリスターもない高意匠の繊維
強化プラスチックを成形することのできる繊維強化プラ
スチックの製造方法を提供することにある。The present invention has been made in view of the above-mentioned problems, and an object of the present invention is to use a non-woven fabric for a decorative sheet without delamination or poor appearance of the non-woven fabric. An object of the present invention is to provide a method for producing a fiber-reinforced plastic capable of molding a high-design fiber-reinforced plastic having no blisters when heated.
【０００５】[0005]
【課題を解決するための手段】上記目的を達成するた
め、本発明に係る繊維強化プラスチックの製造方法は、
熔融温度乃至は融点が繊維強化プラスチックの硬化成形
温度以上の熱可塑性樹脂シートに印刷で絵柄層を形成
し、これに熱硬化性樹脂を含浸させた不織布をその熱硬
化性樹脂が未硬化状態のままで裏打ちしてなる化粧シー
トを用意し、該化粧シートの不織布側と接するように熱
硬化性樹脂からなる繊維強化プラスチックの未硬化物を
積層し、型内で加熱加圧して両者を一体化し、且つ未硬
化の熱硬化性樹脂成分を硬化せしめることを特徴とす
る。In order to achieve the above object, a method for producing a fiber-reinforced plastic according to the present invention comprises:
A pattern layer is formed by printing on a thermoplastic resin sheet whose melting temperature or melting point is equal to or higher than the curing molding temperature of the fiber-reinforced plastic, and a non-woven fabric impregnated with the thermosetting resin is uncured. Prepare a decorative sheet backed as it is, laminate an uncured fiber reinforced plastic made of thermosetting resin so as to be in contact with the nonwoven fabric side of the decorative sheet, and heat and press in a mold to integrate them. And curing an uncured thermosetting resin component.
【０００６】[0006]
【発明の実施の形態】熱可塑性樹脂シートは、ＦＲＰ成
形時に不織布の変形を抑制し得るために流動変形しない
ことが必要である。このため、熱可塑性樹脂シートとし
ては、その熔融温度乃至は融点がＦＲＰ成形温度（通常
１２０〜１６０℃）以上であるものを使用する。具体的
には、（メタ）アクリル酸メチル、（メタ）アクリル酸
エチル、（メタ）アクリル酸ブチル、（メタ）アクリル
酸エチルヘキシル等の（メタ）アクリル酸エステルの単
独又は共重合体等のアクリル樹脂（なお、（メタ）アク
リル酸エステルの表記は「アクリル酸エステル又はメタ
アクリル酸エステル」の意味である）、ポリエチレンテ
レフタレート、ポリブチレンテレフタレート、イソフタ
レート・テレフタレート共重合体等のポリエステル、ポ
リ塩化ビニル、塩化ビニル・アクリル共重合体、塩化ビ
ニル・酢酸ビニル共重合体、エチレン・ビニルアルコー
ル共重合体、エチレン・酢酸ビニル共重合体等のビニル
樹脂、ポリスチレン、アクリロニトリル・スチレン共重
合体、アクリロニトリル・ブタジエン・スチレン共重合
体等のスチレン系樹脂、ポリエチレン、ポリプロピレ
ン、ポリメチルペンテン、オレフィン系熱可塑性エラス
トマー等のオレフィン系樹脂、ナイロン等のポリアミド
樹脂、ポリ弗化ビニル、ポリ弗化ビニリデン等の弗素樹
脂、ポリカーボネート、ポリスチレンナフタレート、ポ
リイミド、ポリフェニレンサルファイド等の樹脂からな
るシート（フィルム）が使用できる。これらのシートの
単層でも或いは異種の物の積層体でもよい。これらの中
でも、ＦＲＰ成形時に作用する応力により亀裂や破断を
生じないためには、加熱時に適当な可撓性を有するもの
が好ましい。この熱可塑性樹脂シートの厚さ（積層体の
場合は総厚）は１０〜３００μｍ程度が好ましい。厚す
ぎるとコスト高になり、逆に薄すぎると成形時に破れや
皺が生じやすくなり、また不織布の変形防止効果も不十
分となる。BEST MODE FOR CARRYING OUT THE INVENTION It is necessary that a thermoplastic resin sheet does not undergo flow deformation in order to suppress deformation of a nonwoven fabric during FRP molding. Therefore, a thermoplastic resin sheet whose melting temperature or melting point is equal to or higher than the FRP molding temperature (normally 120 to 160 ° C.) is used. Specifically, acrylic resins such as homo- or copolymers of (meth) acrylates such as methyl (meth) acrylate, ethyl (meth) acrylate, butyl (meth) acrylate, and ethylhexyl (meth) acrylate (The notation of (meth) acrylate means "acrylate or methacrylate"), polyester such as polyethylene terephthalate, polybutylene terephthalate, isophthalate / terephthalate copolymer, polyvinyl chloride, Vinyl resins such as vinyl chloride / acrylic copolymer, vinyl chloride / vinyl acetate copolymer, ethylene / vinyl alcohol copolymer, ethylene / vinyl acetate copolymer, polystyrene, acrylonitrile / styrene copolymer, acrylonitrile / butadiene / Styrene such as styrene copolymer Resin, polyethylene, polypropylene, polymethylpentene, olefin resin such as olefin thermoplastic elastomer, polyamide resin such as nylon, fluorine resin such as polyvinyl fluoride, polyvinylidene fluoride, polycarbonate, polystyrene naphthalate, polyimide And a sheet (film) made of a resin such as polyphenylene sulfide. These sheets may be a single layer or a laminate of different types. Among them, those which have appropriate flexibility at the time of heating are preferable in order not to cause cracks or breakage due to stress acting at the time of FRP molding. The thickness (total thickness in the case of a laminate) of the thermoplastic resin sheet is preferably about 10 to 300 μm. If the thickness is too thick, the cost increases. On the other hand, if the thickness is too thin, breakage and wrinkles are likely to occur during molding, and the effect of preventing deformation of the nonwoven fabric becomes insufficient.
【０００７】熱可塑性樹脂シートに形成される絵柄層
は、熱可塑性樹脂シートの不織布と接する側に印刷して
もよいし、反対側若しくは両面に印刷してもよい。この
場合、印刷方式はグラビア、オフセット、シルクスクリ
ーン等でよく、また使用する絵柄インキは樹脂バインダ
ーに顔料、染料等の着色剤を添加したものを用いる。バ
インダーとしては、酢酸セルロース、セルロースアセテ
ートプロピオネート、硝化綿等の繊維素樹脂、（メタ）
アクリル酸メチル、（メタ）アクリル酸エチル、（メ
タ）アクリル酸ブチル、（メタ）アクリル酸エチルヘキ
シル等の（メタ）アクリル酸エステルの単独又は共重合
体等のアクリル樹脂、ポリウレタン樹脂、塩化ビニル・
酢酸ビニル共重合体、ポリエステル等の１種又は２種以
上の混合物が、顔料としては、弁柄、カドミウムレッ
ド、黄鉛、群青、チタン白、カーボンブラック、２酸化
チタン被覆雲母等の無機顔料、キナクリドン、ポリア
ゾ、イソインドリノン、フタロシアニンブルー等の有機
顔料等が用いられる。なお、印刷する絵柄は、木目柄、
石目柄、布目柄等の天然物の絵柄、幾何学模様、文字、
記号、全面ベタ等のいずれであってもよい。The pattern layer formed on the thermoplastic resin sheet may be printed on the thermoplastic resin sheet in contact with the nonwoven fabric, or on the opposite side or on both sides. In this case, the printing method may be gravure, offset, silk screen, or the like, and the pattern ink used is a resin binder to which a coloring agent such as a pigment or a dye is added. As the binder, cellulose acetate, cellulose acetate propionate, cellulose resin such as nitrified cotton, (meth)
Acrylic resin such as methyl acrylate, ethyl (meth) acrylate, butyl (meth) acrylate, ethyl hexyl (meth) acrylate, or homopolymer of (meth) acrylate, polyurethane resin, vinyl chloride
One or a mixture of two or more kinds of vinyl acetate copolymers, polyesters, and the like, as pigments, red pigments, cadmium red, graphite, ultramarine, titanium white, carbon black, inorganic pigments such as titanium dioxide-coated mica, Organic pigments such as quinacridone, polyazo, isoindolinone, and phthalocyanine blue are used. The pattern to be printed is wood grain,
Natural products such as stone patterns, cloth patterns, geometric patterns, letters,
Any of a symbol, a solid surface, etc. may be used.
【０００８】不織布としては、アクリル樹脂、ナイロ
ン、ポリエステル樹脂、ポリエチレン、ポリプロピレ
ン、レーヨン、アセテート、ポリ塩化ビニル、セルロー
ス系樹脂、パルプ、ビニロン等の有機物繊維、或いは、
硝子繊維、石綿、チタン酸カリウム繊維、アルミナ繊
維、シリカ繊維、炭素繊維等の無機質繊維を用いた不織
布、和紙等が使用される。なお、コスト、物性、加工
性、強度等を考慮するとポリエステル系樹脂の繊維が好
ましい。そして、本発明で使用する不織布は、厚さが
０．２ｍｍ以下で、その引張強度が通常のＦＲＰ成形温
度（１２０〜１６０℃）で２．０ｋｇ／１５ｍｍ幅以上
のものであることが好ましい。不織布の厚さが０．２ｍ
ｍより大きいと成形時に成形品の端部や曲面部での回り
込みがよくなく、また引張強度が２．０ｋｇ／１５ｍｍ
幅より小さいと破れて接着不良を生じるようになる。As the nonwoven fabric, organic fibers such as acrylic resin, nylon, polyester resin, polyethylene, polypropylene, rayon, acetate, polyvinyl chloride, cellulosic resin, pulp and vinylon, or
Nonwoven fabrics and Japanese paper using inorganic fibers such as glass fibers, asbestos, potassium titanate fibers, alumina fibers, silica fibers, and carbon fibers are used. In consideration of cost, physical properties, workability, strength, and the like, polyester-based resin fibers are preferable. The nonwoven fabric used in the present invention preferably has a thickness of 0.2 mm or less and a tensile strength of 2.0 kg / 15 mm width or more at a normal FRP molding temperature (120 to 160 ° C). Non-woven fabric thickness is 0.2m
If it is larger than m, the wraparound at the end or the curved surface of the molded product is not good during molding, and the tensile strength is 2.0 kg / 15 mm.
If it is smaller than the width, it will be broken and cause poor adhesion.
【０００９】不織布に含浸する熱硬化性樹脂としては、
ＤＡＰ（ジアリルフタレート）樹脂、メラミン樹脂、ベ
ンゾグアナミン樹脂、フェノール樹脂、不飽和ポリエス
テル樹脂、エポキシ樹脂、ウレタン樹脂、尿素樹脂等が
用いられる。そして、浸漬、吹付け等の手段で不織布に
含浸する。不織布に含浸させる熱可塑性樹脂の量は１０
〜２００ｇ／ｍ2 が好ましい。そして、含浸させた熱硬
化性樹脂が未硬化（乃至は不完全硬化）状態でＦＲＰの
未硬化物と積層すると接着性の点で好ましい。熱硬化性
樹脂を含浸させた不織布と前記熱可塑性樹脂シートは公
知の適当な方法で貼り合わせて化粧シートとすればよ
い。例えば、２液硬化型ウレタン樹脂等の接着剤を用い
たドライラミネート法等がある。As the thermosetting resin impregnated into the nonwoven fabric,
DAP (diallyl phthalate) resin, melamine resin, benzoguanamine resin, phenol resin, unsaturated polyester resin, epoxy resin, urethane resin, urea resin and the like are used. Then, the nonwoven fabric is impregnated by means such as immersion or spraying. The amount of thermoplastic resin impregnated into the nonwoven fabric is 10
~200g / m 2 is preferred. Then, it is preferable from the viewpoint of adhesiveness that the impregnated thermosetting resin is laminated with an uncured FRP in an uncured (or incompletely cured) state. The nonwoven fabric impregnated with the thermosetting resin and the thermoplastic resin sheet may be bonded to each other by a known appropriate method to form a decorative sheet. For example, there is a dry lamination method using an adhesive such as a two-component curable urethane resin.
【００１０】繊維強化プラスチック（ＦＲＰ）の未硬化
物としては、ＳＭＣ、ＢＭＣ等の公知のものが各種用い
られる。中でも代表的なものはＳＭＣであり、以下にＳ
ＭＣについて詳述する。ＳＭＣは、熱硬化性樹脂である
不飽和ポリエステル樹脂、エポキシ樹脂、フェノール樹
脂等の樹脂に、ガラス繊維などの強化材を混合したシー
ト状の成形材料であり、金型に入れて加熱加圧すること
によって熱硬化性樹脂が硬化してＦＲＰ製品が得られる
ものである。その製造方法としては、例えば、ポリエチ
レンテレフタレートフィルム等の第１のセパレーターフ
ィルムの片面に、樹脂のプレポリマー、硬化触媒、促進
剤、硬化遅延剤、空気乾燥剤等および、炭酸カルシウ
ム、タルク、クレー等の充填剤等を混練してなる樹脂コ
ンパウンドをナイフコート法等により塗布した上に、ガ
ラス繊維を束ねてなるガラスロービングを切断してなる
チョップストランドを散布し、別に第２のセパレーター
フィルムの片面に、第１のセパレーターフィルムの片面
に塗布したのと同様な樹脂コンパウンドを、同様な塗布
方法により塗布した後、第１のセパレーターフィルムと
第２のセパレーターフィルムを両セパレーターフィルム
の樹脂コンパウンド塗布面どうしが散布されたチョップ
ストランドを介して対向するように重ね合わせ、ロール
加圧にて加圧することにより樹脂コンパウンドを散布さ
れたチョップストランドに含浸・脱泡し、加湿して養生
する方法が採られる。このＳＭＣを製造する際の樹脂と
しては特に限定されないが、通常、不飽和ポリエステル
樹脂やエポキシ樹脂が多い。As the uncured material of the fiber reinforced plastic (FRP), various known materials such as SMC and BMC are used. Among them, the typical one is SMC.
The MC will be described in detail. SMC is a sheet-like molding material in which a reinforcing material such as glass fiber is mixed with a thermosetting resin such as an unsaturated polyester resin, an epoxy resin, or a phenol resin. This cures the thermosetting resin to obtain an FRP product. For example, a resin prepolymer, a curing catalyst, an accelerator, a curing retarder, an air drying agent, and the like, and calcium carbonate, talc, clay, and the like are formed on one surface of a first separator film such as a polyethylene terephthalate film. A resin compound obtained by kneading a filler or the like is applied by a knife coat method or the like, and then a chop strand obtained by cutting a glass roving obtained by bundling glass fibers is sprayed, and separately on one surface of a second separator film. After applying the same resin compound as that applied to one surface of the first separator film by the same application method, the first separator film and the second separator film are coated with the resin compound applied surfaces of both separator films. Facing each other through the scattered chop strands Overlay, and impregnation and defoaming the chopped strands are sprayed resin compound by pressurizing a roll pressure, a method of curing are taken humidified. The resin used for producing the SMC is not particularly limited, but usually includes many unsaturated polyester resins and epoxy resins.
【００１１】化粧シートの不織布側と接するように繊維
強化プラスチック（ＦＲＰ）の未硬化物を積層し、金型
内で加熱加圧して両者を一体化するＦＲＰ成形条件は、
通常成形温度が１２０〜１６０℃、成形圧力が２０〜１
００ｋｇ／ｃｍ2 、成形時間が５〜２０分である。そし
て、成形物の形状は、平板、曲面板、浴槽等の立体物等
である。なお、成形時にエアー噛みを生じやすい形状の
場合、化粧シートの全面に微細孔を設けておいてもよ
い。[0011] The FRP molding conditions for laminating an uncured fiber reinforced plastic (FRP) so as to be in contact with the nonwoven fabric side of the decorative sheet, and heating and pressurizing in a mold to integrate the two are as follows:
Normal molding temperature is 120 ~ 160 ℃, molding pressure is 20 ~ 1
00 kg / cm 2 and molding time is 5 to 20 minutes. The shape of the molded product is a three-dimensional object such as a flat plate, a curved plate, or a bathtub. In the case of a shape that is likely to cause air biting during molding, fine holes may be provided on the entire surface of the decorative sheet.
【００１２】[0012]
【実施例】以下、図面を参照しながら本発明の実施例に
ついて説明する。Embodiments of the present invention will be described below with reference to the drawings.
【００１３】（実施例１）熱可塑性樹脂シート１とし
て、厚さが５０μｍで熔融温度が２６４℃の２軸延伸Ｐ
ＥＴ（ポリエチレンテレフタレート）フィルムを準備し
た。そしてその片面に、アクリルポリオールとヘキサメ
チレンジイソシアネートからなる２液硬化型ウレタン樹
脂のバインダーと顔料とからなるインキを用いてグラビ
ア印刷により大理石模様の絵柄層２を形成した。一方、
ポリエステル系樹脂からなる坪量４０ｇ／ｍ2 の不織布
３を準備し、これにジアリルフタレート（ＤＡＰ）樹脂
のプレポリマーを浸漬により５０ｇ／ｍ2 含浸させた
後、８０℃で５分間乾燥させた。この時点でＤＡＰ樹脂
は未硬化状態である。そして、ウレタン系接着剤（主
剤：アクリルポリオール、硬化剤：ヘキサメチレンジイ
ソシアネート）を用い、この接着剤４を介して、熱可塑
性樹脂シート１の絵柄層２を設けた側に不織布３が向か
い合う状態でドライラミネートし、図１に示す化粧シー
ト５を作製した。(Example 1) As a thermoplastic resin sheet 1, biaxial stretching P having a thickness of 50 μm and a melting temperature of 264 ° C.
An ET (polyethylene terephthalate) film was prepared. Then, a marble pattern layer 2 was formed on one surface thereof by gravure printing using an ink composed of a binder of a two-component curable urethane resin composed of acrylic polyol and hexamethylene diisocyanate and a pigment. on the other hand,
A nonwoven fabric 3 made of a polyester resin and having a basis weight of 40 g / m 2 was prepared, impregnated with a prepolymer of diallyl phthalate (DAP) resin at 50 g / m 2 by dipping, and dried at 80 ° C. for 5 minutes. At this point, the DAP resin is in an uncured state. Then, using a urethane-based adhesive (main agent: acrylic polyol, curing agent: hexamethylene diisocyanate), the nonwoven fabric 3 faces the thermoplastic resin sheet 1 on the side where the pattern layer 2 is provided via the adhesive 4. The decorative sheet 5 shown in FIG. 1 was produced by dry lamination.
【００１４】繊維強化プラスチックの未硬化物として昭
和高分子（株）製「リゴラックＳＭＣ」を準備した。こ
のＳＭＣは、不飽和ポリエステル樹脂プレポリマーと、
スチレン単量体（反応性稀釈剤）と、ナフテン酸コバル
ト（硬化触媒）と、メチルエチルケトンパーオキサイド
（重合開始剤）の混合物を硝子マットに含浸したもので
ある。そして、図２に示すように、上記化粧シート５の
不織布３と接する面にこのＳＭＣ６を重ね合わせ、１５
０℃温度、７５ｋｇｆ／ｃｍ2 圧力で５分間加熱加圧
し、ＳＭＣ６及び不織布３中の熱硬化性樹脂を硬化さ
せ、一体化させた化粧パネルを得た。このようにして製
造した化粧パネルは、層間の接着が良好であり、柄の破
れや歪、残留エアー等外観不良のない高意匠なものであ
った。"Rigolac SMC" manufactured by Showa Polymer Co., Ltd. was prepared as an uncured fiber reinforced plastic. The SMC comprises an unsaturated polyester resin prepolymer,
A glass mat is impregnated with a mixture of styrene monomer (reactive diluent), cobalt naphthenate (curing catalyst), and methyl ethyl ketone peroxide (polymerization initiator). Then, as shown in FIG. 2, the SMC 6 is superimposed on the surface of the decorative sheet 5 which is in contact with the nonwoven fabric 3, and
Heating and pressurizing was performed at a temperature of 0 ° C. and a pressure of 75 kgf / cm 2 for 5 minutes to cure the thermosetting resin in the SMC 6 and the nonwoven fabric 3 to obtain an integrated decorative panel. The decorative panel manufactured in this way had a good design with good adhesion between layers and no appearance defects such as pattern tear, distortion, and residual air.
【００１５】（実施例２）実施例１と同様な化粧シート
を作製し、図３に示すように、その化粧シート５をロー
ルニードルパンチのゴムロール７と針ロール８の間を通
し、シート全面に多数の微細孔を設けた。具体的には、
径０．１ｍｍφの微細孔を２５個／ｃｍ2の密度で設け
た。この微細孔を設けた化粧シートを用いて実施例１と
同様にＳＭＣ同時成形を行い、層間の接着が良好であ
り、柄の破れや歪、残留エアー等外観不良のない良好な
化粧パネルを得た。(Example 2) A decorative sheet similar to that in Example 1 was prepared, and the decorative sheet 5 was passed between a rubber roll 7 and a needle roll 8 of a roll needle punch as shown in FIG. Many micro holes were provided. In particular,
Micropores having a diameter of 0.1 mmφ were provided at a density of 25 / cm 2 . Using the decorative sheet provided with the fine holes, SMC simultaneous molding was performed in the same manner as in Example 1 to obtain a good decorative panel having good adhesion between layers and no appearance defects such as pattern breakage, distortion, and residual air. Was.
【００１６】[0016]
【発明の効果】以上説明したように、本発明の製造方法
によれば、熔融温度乃至は融点が繊維強化プラスチック
の硬化成形温度以上の熱可塑性樹脂シートを用いること
で、鮮明な絵柄印刷ができ、成形の際の熱圧による応力
や歪みに対しても破損することがない。また、不織布に
熱硬化性樹脂を含浸させることで、不織布の層間剥離や
残留エアーの問題がなくなり、得られる繊維強化プラス
チックにおける表面の化粧シートに絵柄の歪や亀裂が発
生せず、綺麗な絵柄を設けることができ、したがって層
間の接着も良好で、表面意匠の優れた繊維強化プラスチ
ックを成形することができる。As described above, according to the manufacturing method of the present invention, a clear pattern can be printed by using a thermoplastic resin sheet whose melting temperature or melting point is higher than the curing molding temperature of fiber reinforced plastic. Also, there is no breakage due to stress or strain due to heat and pressure during molding. In addition, by impregnating the non-woven fabric with the thermosetting resin, the problem of delamination of the non-woven fabric and residual air is eliminated, and the decorative sheet on the surface of the obtained fiber-reinforced plastic does not generate pattern distortion or cracks, and has a beautiful pattern. Therefore, the adhesion between the layers is good, and a fiber-reinforced plastic having an excellent surface design can be formed.
【図１】化粧シートの一例を示す断面図である。FIG. 1 is a sectional view showing an example of a decorative sheet.
【図２】図１の化粧シートとＳＭＣを積層した状態を示
す断面図である。FIG. 2 is a cross-sectional view showing a state in which the decorative sheet of FIG. 1 and SMC are stacked.
【図３】化粧シートに微細孔を形成する様子を示す説明
図である。FIG. 3 is an explanatory view showing a state in which fine holes are formed in a decorative sheet.
１ 熱可塑性樹脂シート ２ 絵柄層 ３ 不織布 ４ 接着剤 ５ 化粧シート ６ ＳＭＣ ７ ゴムロール ８ 針ロール DESCRIPTION OF SYMBOLS 1 Thermoplastic resin sheet 2 Picture layer 3 Nonwoven fabric 4 Adhesive 5 Decorative sheet 6 SMC 7 Rubber roll 8 Needle roll
───────────────────────────────────────────────────── フロントページの続き (51)Int.Cl.6 識別記号 ＦＩ Ｂ２９Ｌ 9:00 31:10 31:44 ──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. 6 Identification code FI B29L 9:00 31:10 31:44
Claims (2)
ックの硬化成形温度以上の熱可塑性樹脂シートに印刷で
絵柄層を形成し、これに熱硬化性樹脂を含浸させた不織
布をその熱硬化性樹脂が未硬化状態のままで裏打ちして
なる化粧シートを用意し、該化粧シートの不織布側と接
するように熱硬化性樹脂からなる繊維強化プラスチック
の未硬化物を積層し、型内で加熱加圧して両者を一体化
し、且つ未硬化の熱硬化性樹脂成分を硬化せしめること
を特徴とする繊維強化プラスチックの製造方法。1. A nonwoven fabric obtained by printing a pattern layer on a thermoplastic resin sheet having a melting temperature or melting point higher than a curing molding temperature of a fiber-reinforced plastic and impregnating the same with a thermosetting resin. Prepare a decorative sheet backed in the uncured state, laminate an uncured fiber-reinforced plastic made of thermosetting resin so as to be in contact with the nonwoven fabric side of the decorative sheet, and heat and press in a mold. A method for producing a fiber-reinforced plastic, characterized in that both are integrated with each other and an uncured thermosetting resin component is cured.
する請求項１に記載の繊維強化プラスチックの製造方
法。2. The method for producing a fiber-reinforced plastic according to claim 1, wherein a decorative sheet provided with fine holes on the entire surface is used.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP9289314A JPH11123735A (en) | 1997-10-22 | 1997-10-22 | Production of fiber reinforced plastic |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP9289314A JPH11123735A (en) | 1997-10-22 | 1997-10-22 | Production of fiber reinforced plastic |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| JPH11123735A true JPH11123735A (en) | 1999-05-11 |
Family
ID=17741590
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP9289314A Pending JPH11123735A (en) | 1997-10-22 | 1997-10-22 | Production of fiber reinforced plastic |
Country Status (1)
| Country | Link |
|---|---|
| JP (1) | JPH11123735A (en) |
Cited By (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| EP1488918A1 (en) * | 2003-01-08 | 2004-12-22 | Yamaha Hatsudoki Kabushiki Kaisha | Decorative sheet, shaped product, automobile, and method for producing shaped product |
| WO2005116157A1 (en) * | 2004-05-25 | 2005-12-08 | Lintec Corporation | Easily applicable pressure-sensitive adhesive sheet and process for production thereof |
| KR101314691B1 (en) * | 2012-05-24 | 2013-10-07 | 주식회사 용산 | Method of making plastic article laminated with velour cloth by press molding |
| JP5428160B2 (en) * | 2005-08-12 | 2014-02-26 | 大日本印刷株式会社 | Decorative plate and method of manufacturing the decorative plate |
| US10214886B2 (en) * | 2013-11-15 | 2019-02-26 | Schock Gmbh | Sanitary basin molded part and method for producing a sanitary basin molded part of this kind |
| JP2019044478A (en) * | 2017-09-01 | 2019-03-22 | タキロンシーアイ株式会社 | Thermoplastic synthetic resin flooring and method for producing the same |
-
1997
- 1997-10-22 JP JP9289314A patent/JPH11123735A/en active Pending
Cited By (9)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| EP1488918A1 (en) * | 2003-01-08 | 2004-12-22 | Yamaha Hatsudoki Kabushiki Kaisha | Decorative sheet, shaped product, automobile, and method for producing shaped product |
| EP1488918A4 (en) * | 2003-01-08 | 2009-05-06 | Yamaha Motor Co Ltd | Decorative sheet, shaped product, automobile, and method for producing shaped product |
| US8080124B2 (en) | 2003-01-08 | 2011-12-20 | Yamaha Hatsudoki Kabushiki Kaisha | Production method of a molded article |
| WO2005116157A1 (en) * | 2004-05-25 | 2005-12-08 | Lintec Corporation | Easily applicable pressure-sensitive adhesive sheet and process for production thereof |
| JP5428160B2 (en) * | 2005-08-12 | 2014-02-26 | 大日本印刷株式会社 | Decorative plate and method of manufacturing the decorative plate |
| KR101314691B1 (en) * | 2012-05-24 | 2013-10-07 | 주식회사 용산 | Method of making plastic article laminated with velour cloth by press molding |
| US10214886B2 (en) * | 2013-11-15 | 2019-02-26 | Schock Gmbh | Sanitary basin molded part and method for producing a sanitary basin molded part of this kind |
| US10640958B2 (en) | 2013-11-15 | 2020-05-05 | Schock Gmbh | Sanitary basin moulded part |
| JP2019044478A (en) * | 2017-09-01 | 2019-03-22 | タキロンシーアイ株式会社 | Thermoplastic synthetic resin flooring and method for producing the same |
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