JP3342240B2 - Method for manufacturing resin molded products - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing a resin molded article used as a member of a house facility, such as a bathtub.

[0002]

2. Description of the Related Art Conventionally, many resin molded products have been used for members of housing equipment. However, resin molded products requiring large strength such as bathtubs are made of glass fiber reinforced plastic (F).
RP). In manufacturing such a resin molded article of glass fiber reinforced plastic, first, a gel coat resin layer 2 is formed on a molding surface of a molding die 1, and then the gel coat resin layer 2 is formed by a hand lay-up molding method or a spray-up molding method. The glass fiber and the resin were supplied to the surface of the substrate to form the glass fiber reinforced layer 4.

[0003]

However, when the resin molded article is formed by the hand lay-up molding method or the spray-up molding method as described above, the resin is cured by using the roller 20 before the resin of the glass fiber reinforcing layer 4 is cured. It is necessary to perform a defoaming operation as shown in FIG. 3 so that air bubbles do not remain in the glass fiber reinforced layer 4. Therefore, labor required for the defoaming operation is required, and labor saving and productivity improvement are required. It was a hindrance. In addition, it is difficult to completely remove air bubbles from the glass fiber reinforced layer 4 in the defoaming operation shown in FIG. 3, and as shown in FIG. 4 (a), the space between the gel coat resin layer 2 and the glass fiber reinforced layer 4 is reduced. Bubbles 5 sometimes remained.
Since the glass fiber reinforced layer 4 is not in close contact with the gel coat resin layer 2 in the portion where the bubbles 5 remain, the gel coat resin layer 2 cannot be reinforced with the glass fiber reinforced layer 4 and impacts on the bubbles 5. 4B, the gel coat resin layer 2 on the surface side of the bubbles 5 is lost as shown in FIG. 4B, and there is a problem that the appearance of the resin molded product is impaired.

[0004] The present invention has been made in view of the above points, can save manpower and improve productivity, and also prevents the gel coat resin layer from being lost and does not impair the appearance of the resin molded product. It is an object of the present invention to provide a method for producing a resin molded product that can be made as described above.

[0005]

According to a first aspect of the present invention, there is provided a method of manufacturing a resin molded product, comprising: forming a gel coat resin layer on a molding surface of a mold; and forming a glass powder on the surface of the gel coat resin layer. And a resin are mixed to form a reinforcing layer 3 of the gel coat resin layer 2 by spraying a resin mixed with a filler, and a glass fiber 17 and a resin 18 are sprayed on the surface of the reinforcing layer 3 to form a glass fiber reinforced layer 4. Of molded resin products
In the method, a glass powder having a fiber length of 0.05 to 0.5 mm is used.
Powder containing 5 to 20% by weight of the resin
-Prepare mixed resin, cut length of 8mm and 16mm
Mix the scooped strand and mix the glass fiber 17
The glass fiber 17 is jetted and the glass
Inject resin 18 from both sides of fiber 17
The mixture 7 of the resin 18 and the glass fiber 17 of the
The glass fiber reinforced layer 4 is formed by spraying on the surface .

[0006]

Hereinafter, the present invention will be described in detail. The gel coat resin layer 2 can be formed of a gel coat resin. As the gel coat resin, a commercially available resin or a resin prepared by blending a curing agent or a filler with a thermosetting resin such as an unsaturated polyester resin as necessary can be used. Alternatively, a gel coat resin colored with a toner or the like can be used.

The reinforcing layer 3 can be formed of a resin mixed with a filler prepared by mixing a glass powder with a resin such as a thermosetting resin. As the resin of the filler mixed resin,
It is preferable to use an unsaturated polyester resin from the viewpoint of hot water resistance. The glass powder has a fiber length of 0.05 to 0.5.
mm. If the fiber length of the glass powder is less than 0.05 mm, the reinforcing layer 3 cannot be sufficiently reinforced by the glass powder, and the reinforcing performance of the gel coat resin layer 2 by the reinforcing layer 3 may be reduced. If the fiber length of the glass powder exceeds 0.5 mm, entanglement between the glass powders occurs or the affinity between the glass powder and the resin is reduced, and air is mixed into the resin containing the filler, and the air becomes bubbles and is reinforced. There is a risk of remaining in the layer 3.

The above-mentioned filler-containing resin can be prepared by mixing 5 to 20% by weight of glass powder with respect to the resin. If the amount of the glass powder is less than 5% by weight, the resin cannot be sufficiently reinforced with the glass powder, and the reinforcing layer 3
Therefore, the reinforcing effect of the reinforcing layer 3 on the gel coat resin layer 2 may be reduced. If the amount of the glass powder exceeds 20% by weight,
There is a possibility that the viscosity of the resin mixed with the filler becomes too large and spraying by a spray cannot be performed. The filler-containing resin is subjected to a defoaming treatment at this preparation stage, so that almost no air is present in the filler-containing resin.

[0010] By forming the reinforcing layer 3 with a resin mixed with a filler as described above, the strength of the reinforcing layer 3 can be increased as compared with the case where the reinforcing layer 3 is formed with only the resin, and the reinforcing effect of the gel coat resin layer 2 can be improved. Can be higher. Since the resin mixed with the filler has a higher viscosity than the resin, the gel coat resin layer 2 formed on the surface of the mold 1 in the vertical direction is formed.
Resin dripping can be prevented even when sprayed on the surface of the substrate, and the reinforcing layer 3 having a uniform thickness can be easily formed. Further, the glass powder of the reinforcing layer 3 serves as a resistance to the flow of the mixture 7 sprayed on the reinforcing layer 3 to form the glass fiber reinforced layer 4 described later. Even if the mixture 7 is sprayed on the layer 3, the mixture 7 can be prevented from dripping, and the glass fiber reinforcing layer 4 having a uniform thickness can be easily formed.

The glass fiber reinforced layer 4 can be formed of a resin 18 such as a thermosetting resin and glass fibers 17.
As the resin 18 of the glass fiber reinforced layer 4, an unsaturated polyester resin or the like can be used as in the case of the reinforcing layer 3.
The glass fibers 17 of the glass fiber reinforced layer 4 can be prepared by mixing glass chopped strands having a cut length of 8 mm and glass chopped strands having a cut length of 16 mm. The mixing ratio between the cut length of 8 mm and the cut length of 16 mm is preferably 2: 1.
The glass fiber reinforced layer 4 is formed by mixing the glass fiber reinforced layer 4 with the glass fiber 17 including those having only a short cut length by mixing the glass fiber reinforced layer 4 with a material having a short cut length of 16 mm and a material having a cut length of 16 mm. Glass fiber 1 including those which can improve the strength and have only a long cut length.
7, the affinity between the resin 18 and the glass fiber 17 can be improved as compared with the case where the glass fiber reinforced layer 4 is formed.

The glass fiber 17 and the resin 18 are sprayed using a spray device 10 as shown in FIG. This spray device 10 includes a cutter 12 formed in a spray holding body 11 such as a robot hand and provided with a blade portion 12a over the entire circumference, and a cylinder arranged close to the outer circumference of the cutter 12. It is provided with a rubber roller 13, a resin injection nozzle 14, and a glass fiber injection nozzle 15. Two resin injection nozzles 14 are provided on the upper and lower sides of the glass fiber injection nozzle 15, and the glass fiber injection nozzle 1 is disposed between the pair of resin injection nozzles 14.
5 are arranged.

The spray device 10 is provided with a glass roving 16 by rotating a cutter 12 and a rubber roller 13.
Is introduced between the cutter 12 and the rubber roller 13, and the blade 12 a and the rubber roller 13
With the glass roving 16
Is cut to form a glass fiber 17, and this glass fiber 1
7 from the glass fiber injection nozzle 15 toward the reinforcing layer 3 and at the same time, the resin injection nozzles 1 on the upper and lower sides.
4, the resin 18 is sprayed toward the reinforcing layer 3, respectively, and the glass fiber 17 is sandwiched between the resins 18, and the two are mixed in front of the spray device 10 to form a mixture 7. Is to be sprayed. That is, the spray device 10 employs a sandwich gun system in which the glass fibers 17 are sprayed by being sandwiched by the resin 18, and the glass fibers 17 and the resin 18 can be mixed in the air before reaching the reinforcing layer 3. I have.

In the present invention, the glass roving 16
By changing the rotation speed and the like of the cutter 12 at the time of cutting, a glass chopped strand having a cut length of 8 mm and a glass chopped strand having a cut length of 16 mm are prepared, and the glass fibers 17 are mixed by mixing glass chopped strands having different lengths. Creating. As described above, the glass fibers 17 are mixed in the air so as to be sandwiched between the resins 18, and the mixture 7 is sprayed on the surface of the reinforcing layer 3. Therefore, when the glass fibers 17 are ejected by the resins 18 on both sides, the glass fibers 17 are widely spread. It is possible to prevent the glass fiber 17 from jumping out of the resin 18 even if the glass fiber 17 rebounds on the surface of the reinforcing layer 3 and to prevent the glass fiber 17 from scattering.

Next, a process of manufacturing a resin molded product using the above-described materials and equipment will be described. First, the gel coat resin is applied or sprayed on the surface of the mold 1 which has been subjected to a release treatment by applying a release agent or the like, and then cured to form a gel coat resin layer 2. The thickness of the gel coat resin layer 2 is 0.3
mm is preferable. Next, a filler-containing resin is sprayed on the surface of the gel coat resin layer 2 with a spray gun, and then cured to form the reinforcing layer 3. The thickness of the reinforcing layer 3 is 0.4
mm is preferable. Next, the glass fiber 17 and the resin 18 are sprayed on the surface of the reinforcing layer 3 using the spray device 10, and then the resin 18 is cured to form the glass fiber reinforced layer 4. After that, by releasing from the molding die 1,
A resin molded product having a sectional configuration as shown in FIG. 2 can be formed.

In the step of forming the reinforcing layer 3, a resin mixed with a filler is sprayed on the gel coat resin layer 2 using a spray gun as in the conventional spray-up molding method. However, in the conventional spray-up molding method, the resin and the filler such as glass chopped strands are separately sprayed from a spray gun, and the resin and the filler are mixed in the air and sprayed on the gel coat resin layer 2. In the present invention, a filler-containing resin prepared by mixing a resin and glass powder in advance before spraying from a spray gun is sprayed on the gel coat resin layer 2, which is different in this point.

By spraying the filler-containing resin prepared by mixing the resin and the glass powder in advance as in the present invention onto the gel coat resin layer 2, the resin and the glass powder are not mixed in the air, and Air can be prevented from entering the resin. Therefore, it is not necessary to perform a defoaming operation using a roller or the like on the reinforcing layer 3, and it is possible to prevent bubbles from being present in the reinforcing layer 3 even though the reinforcing layer 3 is formed by spraying.

Since no bubbles are present in the reinforcing layer 3, the reinforcing layer 3 can be adhered to the entire back surface of the gel coat resin layer 2, and the entire gel coat resin layer 2 can be reinforced by the reinforcing layer 3. Even if an impact is applied to the portion of the bubble 5 having a diameter of about 3 mm to 5 mm generated in the glass fiber reinforced layer 4, the gel coat resin layer 2 can be prevented from being chipped. Further, since the gel coat resin layer 2 can be reinforced with the reinforcing layer 3 in this manner, some small bubbles may be present in the glass fiber reinforced layer 4.
Therefore, it is not necessary to perform the conventional defoaming operation using the roller 20 on the glass fiber reinforced layer 4, or the defoaming operation on the glass fiber reinforced layer 4 can be reduced or simplified.

[0019]

The present invention will be described below in detail with reference to examples. (Example) As a resin mixed with a filler, a bisphenol-based unsaturated polyester resin having a viscosity of 15 poise / 25 ° C. and thixotropic 4/25 ° C. was 100 PHR, and a fiber length was 0.07 m.
The glass powder of m was prepared by mixing 15 PHR. As the resin 18 forming the glass fiber reinforced layer 4, an isophthalic acid-based unsaturated polyester resin was used. The glass fibers 17 forming the glass fiber reinforced layer 4
Is to cut a glass roving 16 having a weight per unit length of 2310 g / km to a cut length of 8 mm and 16 mm.
mm chopped strands each,
A mixture of a glass chopped strand of 8 mm and a glass chopped strand of 16 mm at a ratio of 2: 1 was used.

Then, a colored gel coat resin is sprayed on the molding surface of the mold 1 that has been subjected to the mold release treatment, and the resin is cured to a thickness of 0.3 m.
m, a gel coat resin layer 2 is formed.
The resin mixed with filler is sprayed on the surface of
A reinforcing layer 3 of 4 mm is formed, and a resin 18 and a glass fiber 17 are sprayed on the surface of the reinforcing layer 3 by using a spray device 10 shown in FIG. 1, and the resin 18 is cured to form a glass fiber reinforced layer 4. The mold was removed to obtain a resin molded product having a cross-sectional configuration as shown in FIG.

As the spraying device 10, HLL-9000 type manufactured by Togiken Co., Ltd. can be exemplified. The spraying conditions are as follows. The resin pressure is 80 kg / cm ² , the resin 18 has a pattern width of 30 cm, and the glass fiber 17 has Pattern width is 2
8 cm. (Comparative Example) As the gel coat resin and the resin 18 for forming the glass fiber reinforced layer, the same resin as in the above-described embodiment was used. As the glass fiber 17 forming the glass fiber reinforced layer, the same glass roving 16 as in the above embodiment was cut to a cut length of 25 mm.
A glass chopped strand prepared by cutting into pieces was used.

Then, a gel coat resin is sprayed on the molding surface of the mold 1 subjected to the mold release treatment to be cured to form a 0.3 mm gel coat resin layer 2, and the conventional spray shown in FIG. Resin 18 using device 10
Then, the glass fiber 17 was sprayed and cured to form the glass fiber reinforced layer 4, and the mold was removed to obtain a resin molded product having a cross-sectional configuration as shown in FIG.

The conventional spray device 10 shown in FIG.
Is a resin injection nozzle 14 located below the glass fiber injection nozzle 15 in the spray device 10 shown in FIG.
It is formed so as to include only the resin injection nozzle 14 located above the glass fiber injection nozzle 15. When forming the comparative example, a glass chopped strand having a fixed length (25 mm) was formed without changing the rotation speed of the cutter 12 and the like, and this was used as the glass fiber 17.

A comparison between the resin molded product of the above example and the resin molded product of the comparative example shows that there was no air bubble in the reinforcing layer 3 formed on the back surface of the gel coat resin layer 2 in the example. In the example, bubbles 5 were present in the glass fiber reinforced layer 4 formed on the back surface of the gel coat resin layer 2. When the shock was applied to the example, the gel coat resin layer 2 did not drop. On the other hand, when the shock was applied to the comparative example, the gel coat resin layer 2 dropped on the surface side of the bubble 5. In the example, scattering of the glass fiber 17 was not observed, but in the comparative example, scattering of the glass fiber 17 was observed.

[0025]

As described above, in the method for producing a resin molded product according to the first aspect of the present invention, a gel coat resin layer is formed on a molding surface of a mold, and glass powder and resin are formed on the surface of the gel coat resin layer. The filler-mixed resin prepared by mixing is sprayed to form a reinforcing layer of the gel coat resin layer, and the glass fiber and the resin are sprayed on the surface of the reinforcing layer to form a glass fiber reinforced layer. By spraying the filler-mixed resin prepared by mixing onto the gel coat resin layer to form a reinforcing layer, it is possible to prevent bubbles from being present in the reinforcing layer, and it is not necessary to perform a defoaming operation on the reinforcing layer. To save labor and improve productivity, and to prevent loss of gel coat resin due to impact so that the appearance of the resin molded product is not impaired. It is those which can be one in which the defect rate of the resin molded article is lowered.

Further, by providing a reinforcing layer of the gel coat resin layer between the gel coat resin layer and the glass fiber reinforced layer, it is possible to prevent the gel coat resin from being chipped even if some bubbles exist in the glass fiber reinforced layer. Therefore, there is no need to simplify the defoaming operation for the glass fiber reinforced layer or to perform the defoaming operation, thereby saving labor and improving productivity.

[0027] Also, fiber維長glass powder by containing 5 to 20 wt% relative to the resin so to prepare a filler mixed resin of 0.05 to 0.5 mm, by using a short glass powder of fiber length It is possible to eliminate the entanglement between the glass powders, increase the familiarity between the resin and the glass powder, and make it difficult for air to be present in the resin mixed with the filler. By containing the glass powder by weight, the resin can be sufficiently reinforced with the glass powder to increase the strength of the reinforcing layer, and the viscosity of the resin mixed with the filler is not excessively increased so that the spraying by the spray is easy. It can be done to.

[0028] Also, since it is configured mosquitoes Tsu preparative length 8mm and glass chopped strands are mixed the glass fibers of 16 mm, a sufficiently high strength of the glass fiber reinforced layer to improve the conformability of the resin and glass fibers Is what you can do. In addition, the glass fiber is sprayed, and a resin is sprayed from both sides of the glass fiber, and a mixture of the resin and the glass fiber is sprayed on the surface of the reinforcing layer to form a glass fiber reinforced layer. The glass fiber injected by the resin can be prevented from spreading widely, and by preventing scattering of the glass fiber, wasteful glass fiber can be reduced and material cost can be reduced. is there.

[Brief description of the drawings]

FIG. 1 is a sectional view showing one embodiment of the present invention.

FIG. 2 is a sectional view showing a part of a resin molded product formed by the present invention.

FIG. 3 is a schematic view showing a conventional defoaming operation.

4A is a cross-sectional view showing a resin molded product formed by a conventional manufacturing method, and FIG. 4B is a cross-sectional view showing a state when an impact is applied to the resin molded product of FIG.

FIG. 5 is a schematic view showing a conventional spray device.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Mold 2 Gel coat resin layer 3 Reinforcement layer 4 Glass fiber reinforcement layer 7 Mixture 17 Glass fiber 18 Resin

──────────────────────────────────────────────────続 き Continued on front page (58) Field surveyed (Int.Cl. ⁷ , DB name) B29C 70/00-70/88

Claims (1)

(57) [Claims] 1. A gel coat resin layer is formed on a molding surface of a mold, and a filler mixed resin prepared by mixing a glass powder and a resin is sprayed on a surface of the gel coat resin layer to form a reinforcing layer of the gel coat resin layer. In the method for producing a resin molded product, wherein a glass fiber and a resin are sprayed on the surface of the reinforcing layer to form a glass fiber reinforced layer , a fiber length of 0.05 to
0.5-20% by weight of glass powder to resin
To prepare the above resin mixed with filler, and cut length 8
mm and 16mm glass chopped strands
To constitute the above glass fiber, and spray this glass fiber
And spray resin from both sides of the glass fiber.
Blow a mixture of leverage resin and glass fiber onto the surface of the reinforcement layer
And forming the glass fiber reinforced layer by attaching the glass fiber reinforced layer .