JPH0768581A - Manufacture of frp molded product with pattern - Google Patents

Abstract

PURPOSE:To provide a manufacturing method capable of applying easily beautifully a specific pattern when an FRP molded product is manufactured by press molding. CONSTITUTION:An FRP molding material 16 such as SMC or the like is set in a molding space 14 between a male mold 10 and a female mold 12 to make an intermediate molded product 18. Thereafter, the mold is once opened, and a prepreg sheet 20 for patterning composed by impregnating a base sheet such as paper, nonwoven fabric, etc., with transparent resin is set on a molding surface of the male mold 10. By fastening the mold again an FRP molded product 24 with a pattern 20 is obtained.

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 an FRP molded product, and more specifically, an FR characterized by a patterning means.
The present invention relates to a method for manufacturing a P molded body.

[0002]

2. Description of the Related Art As a method for manufacturing a waterproof pan or other FRP molded body in a unit bathroom, SMC, BMC
A press-molding method in which an FRP molding material such as the above is pressurized and heated by a pair of male mold and female mold to be molded into a predetermined shape and cured is widely used.

As a method for producing an FRP molded body, there are a method by hand lay-up, a method by spray-up and the like, but the method by press molding has an advantage that mass production is easy. On the other hand, there is a problem that it is difficult to form a pattern on the FRP molded body.

In the method for producing an FRP molded product by this press molding, a method of adding a colored filler or the like to a conventional molding material has been used as a means for applying a pattern. A method of spraying multi-colored ink is known.

However, these methods have the following drawbacks. That is, in the case of the above method, the pattern pattern applied to the molded body is limited to the speckled pattern, and a flow pattern is formed along the flow direction of the molding material that flows at the time of molding, resulting in a uniform decorative pattern. In addition, in the case of the present method, most of the colored fillers are buried inside the molded body, and the surface fillers that contribute to the development of the pattern are a very small part of the whole, and therefore a large amount. However, there is a problem in that the cost is high because the expensive colored filler is required.

On the other hand, in the case of the latter method, there is a problem that the pattern pattern is limited to the spot pattern as in the case of the method of (2), and the step of applying the pattern pattern is required as a separate step.

On the other hand, as shown in FIG. 3, a prepreg sheet 100 for patterning, which is obtained by impregnating a non-woven fabric with a transparent resin, is placed on the molding surface of a molding die 102, and SMC or the like is further molded. The FRP which applies the decorative pattern 108 based on the prepreg sheet 100 to the molded body by setting the material 104, clamping the molding dies 102 and 106, and then molding and curing the molding material 104 under pressure and heat. A method for manufacturing a molded body has been proposed (Japanese Patent Laid-Open No. Hei 4)
-341809).

[0008]

However, in this method, when the molding material 104 is clamped and the molding material 104 such as SMC is fluidized in the molding space, the prepreg sheet 100 is also fluidized, and a pattern is formed at a fixed position. There is a problem that it can not be done or the pattern is broken.

In addition to the above, the molding material 10 is formed in the molding space.
When 4 flows, a large tensile force acts on the prepreg sheet 100, which causes a problem that the prepreg sheet 100 is broken.

[0010]

The present invention has been made to solve the above problems. Thus, according to the invention of the present application, the FRP molding material such as SMC or BMC is set in the molding space of the molding die, and the molding material is pressure-heated by performing the mold clamping operation, after which the molding material is completely cured. A pattern formed by temporarily opening the molding die at a stage before reaching the self-shape retention property and impregnating the molding surface of the molding die with a transparent resin into a base sheet such as paper or nonwoven fabric having a pattern. A prepreg sheet for attachment is set, and then the molding die is clamped again to completely cure the molding material and the prepreg sheet, and at the same time, the prepreg sheet is integrally fused to a molded body ( Claim 1).

In another aspect of the present invention, the molded body is formed into a shape having a recess for fusing the prepreg sheet, and the prepreg sheet is set on the recessed part of the mold. And its end is located at the end of the recess molding portion (claim 2).

[0012]

As described above, according to the first aspect of the present invention, the FRP molding material such as SMC is set in the molding space and the first stage of the mold clamping is performed, so that the molding material is sufficiently filled in the molding space. The material is made to flow to form the shape, and the mold is once opened before the molding material is completely cured and has a self-shape retention property. After being set on the molding surface, the mold is clamped again to completely cure the molding material and the prepreg sheet to obtain an FRP molded product.

According to the present invention, since the prepreg sheet for patterning does not flow together with the molding material at the time of mold clamping, it is possible to accurately apply the pattern to a predetermined fixed position of the FRP molded body. In addition, since there is no fear that the prepreg sheet is broken by the tensile force due to the flow of the molding material, it is possible to impart a complete pattern to the FRP molded body.

In addition, since the prepreg sheet for patterning is integrally fused with the molding material and cured, a clean pattern is formed on the FRP molded body.

According to a second aspect of the present invention, the FRP molded body is formed into a shape having a predetermined recess, and the prepreg sheet is fused at the recess, and the end of the recess is aligned with the end of the prepreg sheet. This is what you do.

In this way, the end of the patterned portion is F
It is possible to prevent it from protruding from the RP molded body, and to prevent the danger that the patterned portion is peeled off from the end face.

[0017]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment in which the present invention is applied to the production of a waterproof pan for a unit bathroom will be described in detail with reference to the drawings.

In FIG. 1, 10 is a male type and 12 is a female type.
4 is a molding space formed between them. The molding space 14 has a shape corresponding to the shape of the waterproof pan 24 (see (V)).

Here, as shown in (V), the waterproof pan has a bathtub mounting portion 24a and a washing place side portion 24b, and a predetermined recess 26 is formed in the washing place side portion 24b.
(See FIG. 2A).

The recess 26 is a portion where the prepreg sheet 20 described later is fused, but when the prepreg sheet 20 is not fused as in the method of this example, a decorative material such as a tile is attached. It can be used as a part of.

In the method of this example, first, as shown in (I), the FRP molding material 16 such as SMC or BMC is placed on the molding surface of the male mold 10 with the male mold 10 and the female mold 12 opened. Place.

Then, as shown in (II), a male mold 10
And the female mold 12 are closed (mold clamping) to form the molding material 1
6. Pressurize and heat 6 at a predetermined pressure. At this stage, the molding material 16 flows in the molding space 14 to fill the space 14 and the curing reaction proceeds by heating.

When the curing reaction of the molding material 16 has progressed to a certain extent, specifically, at the stage where the molding material 16 has not yet been completely cured and has become an intermediate molded product 18 and has self-shape retention. , (III), once male 10
And the female mold 12 are opened. At this time, the intermediate molded product 18 is attached to the female mold 12.

Now, when the male mold 10 and the female mold 12 are opened, as shown in (IV), a paper having a predetermined pattern on the molding surface of the washing room side molding portion of the male mold 10,
A prepreg sheet 20 for patterning is formed by impregnating a base sheet such as a non-woven fabric with a transparent resin.

The male mold 10 is formed with a protruding molding portion 30 for molding the recess 26 (see FIG. 2A) of the FRP molded body (waterproof pan 24). In the step of placing the prepreg sheet 20), the prepreg sheet 20 is formed into the recess 26 and the protruding molding portion 30 for molding.
Is placed and set so that its end substantially coincides with the end of the molding portion 30.

In this way, the prepreg sheet 20 is attached to the male mold 1
After being placed on the molding surface of 0, the male mold 10 and the female mold 12 are clamped again, and the intermediate molded product 18 and the prepreg sheet 2
0 is pressurized and heated at a predetermined pressure.

At this stage, the molding material does not flow in the molding space 14, so that the newly set prepreg sheet 20 does not move or break as the molding material flows.

When (V) pressure heating is performed by the mold clamping, the curing reaction of the intermediate molded product 18 and the newly set prepreg sheet 20 proceeds, and when they are completely cured, the male mold 10 and the female mold 10 are cured. 12 and mold open, F
The RP molded body is demolded.

Here, a waterproof pan 24 as an FRP molded body having a predetermined decorative pattern 22 on the upper surface of the washing place side portion 24b is obtained.

The end of the prepreg sheet 20 set in the step (IV) is the recess 2 of the washing-side portion 24b.
Since it is located at the end of No. 6, that is, at the step portion 28 (see FIG. 2A), it is possible to prevent the end of the prepreg sheet 20 (strictly speaking, its cured body) from protruding to the surface of the molded body. The appearance can be finished neatly, and the risk that the cured portion of the prepreg sheet peels off from the end can be prevented.

The embodiments of the present invention have been described in detail above, but this is merely an example, and the present invention can be applied to the production of various FRP molded bodies other than the above-mentioned waterproof pan. The present invention can be implemented in a mode in which various changes are made based on the knowledge of those skilled in the art without departing from the scope.

[Brief description of drawings]

FIG. 1 is an explanatory view of a specific procedure of a method for manufacturing an FRP molded body which is an embodiment of the present invention.

FIG. 2 is an enlarged view of a main part in FIG.

FIG. 3 is a diagram showing an example of a conventionally known method for manufacturing an FRP molded body.

[Explanation of symbols]

 10 Male Mold 12 Female Mold 14 Molding Space 16 Molding Material 18 Intermediate Molded Product 20 Prepreg Sheet 22 Decorative Pattern 24 Waterproof Pan (Molded Product) 26 Recess 30 Recess Molded Part

Claims (2)

[Claims] 1. An FRP molding material such as SMC or BMC is set in a molding space of a molding die, and a clamping operation is performed to heat the molding material under pressure, after which the molding material is completely cured. Paper having a pattern on the molding surface of the mold by once opening the mold at the stage of having self-shape retention property,
A prepreg sheet for patterning is set by impregnating a base resin such as a non-woven fabric with a transparent resin, and then the mold is clamped again to completely cure the molding material and the prepreg sheet and form the prepreg sheet. A method for producing a patterned FRP molded article, which comprises integrally fusing to a body. 2. The molded body is formed in a shape having a recess for fusing the prepreg sheet, and the prepreg sheet is set on the recessed part of the mold and the end thereof is recessed. A method for producing an FRP molded body, which is characterized in that the FRP molded body is positioned at an end of a molded portion.