JPH08142205A - Molding of resin molded product - Google Patents

Abstract

PURPOSE: To produce a coated molded product free from voids by arranging a block of a thermoplastic resin molding material in a split mold to heat and pressurize the block to cure or semicure the same and injecting a coating material into the mold in this state to form the coated molded product. CONSTITUTION: A thermoplastic resin molding material 1 is compressed to a degree not generating curing reaction in a separate mold before arranged in a split mold 2 to form a block 1A having a flat surface. This block 1A is arranged in the split mold 2 and pressurized under heating to be cured or semicured and, in this state, a coating material 4 is injected into the split mold 2 to form a coated molded product. Since the block 1A of the thermoplastic resin molding material having a flat surface is formed by the separate mold prior to molding the same by the split mold 2, no air is involved in the sheet like thermoplastic resin molding material 1 or in the gap between the block 1A and the mold 2 at the time of molding and the generation of voids can be eliminated.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for molding a thermosetting resin molding material by heat and pressure molding using a split mold, and injecting a coating material into the split mold in a cured or semi-cured state. The present invention relates to an in-mold coating molding method for forming a coating layer on the surface of a molded product.

[0002]

2. Description of the Related Art Conventionally, a thermosetting resin molding material is heated and pressure-molded using a split mold, and a coating material is injected into the split mold in a cured or semi-cured state so that at least one of the surfaces of the mold can be covered. A method for forming a coating layer in a mold is known from JP-B-55-9291.

In this conventional example, a thermosetting resin molding material is placed in a split mold, compression molding is performed, and then a coating material is injected to perform mold molding in a mold.
Thermosetting resin molding materials such as molding compounds have irregularities on the surface, and when a certain amount of these are laminated, a gas such as air remains between BMCs or between BMCs and split molds, and is obtained. The molded product has a problem that a defective molded product called a void in which the gas remains is generated.

[0004]

SUMMARY OF THE INVENTION The present invention has been made in view of the above points, and its purpose is to:
It is an object of the present invention to provide a method for molding a resin molded product, which can manufacture a coated molded product without generation of voids.

[0005]

In order to solve the problems of the above-mentioned conventional examples and to achieve the object of the present invention, the method for molding a resin molded product of the present invention is such that a thermosetting resin molding material 1 is divided into metal pieces. A coating material 4 is injected into the split mold 2 in a state of being heated and pressed by the mold 2 to be cured or semi-cured, and is heated and pressed again to form a coating layer 5 on the surface of the resin molded product 3. In the molding method of a molded article, the sheet-shaped thermosetting resin molding material is provided between the molds 6 different from the split molds 2 which are set so that the sheet-shaped thermosetting resin molding material 1 does not cause a curing reaction. 1 for stacking and arranging 1 and the die 6
Sheet-shaped thermosetting resin molding material 1 laminated by
To obtain a block 1A of a thermosetting resin molding material having a flat surface, and arranging the block 1A of the thermosetting resin molding material in a split mold 2 to heat or press to cure or semi-cure it. Coating material 4 in the split mold 2 in the state
Is injected to form a coated molded article.

[0006]

According to the present invention of the method as described above, the thermosetting resin molding material 1 placed in the split mold 2 is replaced with the split mold 2.
Before being placed in the mold, a block 1A of thermosetting resin molding material having a flat surface is obtained by compressing by another mold 6 to such an extent that a curing reaction does not occur, and the block 1A of thermosetting resin molding material having a flat surface. Is placed in the split mold 2 and is heated and pressed to be cured or semi-cured, and then the coating material 4 is injected into the split mold 2 in a state where the resin molded product 3 is cured or semi-cured to perform cover molding. As described above, a block 1A made of a thermosetting resin molding material having a flat surface is formed by another mold 6 prior to the molding by the divided mold 2 in this manner. No air is entrained between the sheet-shaped thermosetting resin molding material 1 at the time of molding, and since the surface of the block 1A of the thermosetting resin molding material is flat, the block 1A of the thermosetting resin molding material and the split mold Air is also included between 2 Possible so that there is no door.

[0007]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described below in detail with reference to the embodiments shown in the accompanying drawings. 1 to 4 show the order of forming the block 1A of the thermosetting resin molding material by the mold 6, and FIGS. 5 to 10 show the molding process of the in-mold coating molding. The mold 6 used in the steps of FIGS. 1 to 4 and FIGS.
It is different from the split mold 2 used in the step 0. FIG.
The mold 6 used in the process of FIG. 4 is composed of a lower mold 6a and an upper mold 6b. In the embodiment shown in the accompanying drawings, the lower mold 6a is a fixed mold and the upper mold 6b is a movable mold. The upper die 6b is adapted to move in the vertical direction by a cylinder device such as a cylinder. A vacuum pump 7 is connected to the mold 6.

The split mold 2 is composed of a first split mold 2a serving as a lower mold and a second molding mold 2b serving as an upper mold. In the embodiment shown in the accompanying drawings, The mold 2a is a fixed mold, the second mold 2b is a movable mold, and the second mold 2b is moved vertically by a cylinder device such as a hydraulic cylinder. An injection port 8 is provided in the first molding die 2a, and a coating material 4 such as a molding resin for forming the coating layer 5 contained in the tank 11 is filled with a coating material supply device 1 such as an injection cylinder.
0 allows injection from the injection port 8. Here, an opening / closing valve 12 is provided at the injection port 8a.

First, as shown in FIG. 1, a sheet-like thermosetting resin molding material 1 as shown in FIG. 11 is required for the lower mold 6a while the upper mold 6b of the mold 6 is raised. Multiple sheets are stacked and placed. Here, a glass fiber reinforced thermosetting resin is used as the thermosetting resin molding material 1, and unsaturated polyester resin or the like is used as a filler such as calcium carbonate or aluminum hydroxide, a curing agent, or a fiber such as glass fiber or carbon fiber. BMC (bulk molding compound) with a reinforcing agent, thickener and colorant if necessary
And the like are used. In the embodiment, the size of BMC is 100 × 100 × 15 and three layers are laminated. Next, as shown in FIG. 2, the upper mold 6b is lowered to close the mold, and the thermosetting resin molding material 1 is pressed. Next, as shown in FIG. 3, the vacuum pump 7 is operated with the mold closed to exhaust the air in the mold 6. Next, the vacuum pump 7 is stopped, and the upper mold 6 as shown in FIG.
b is raised, and then the thermosetting resin molding material 1 in the lower mold 6a is taken out. The thermosetting resin molding material 1 thus taken out is a block 1A of the thermosetting resin molding material having a flat surface. Here, the molding by the mold 6 is set to such an extent that the thermosetting resin molding material 1 does not cause a curing reaction. The molding conditions for this mold 6 are
The mold temperature is about 50 to 80 ° C. and the pressing time is about 3 to 5 minutes.

Next, as shown in FIG. 5, the second mold 2b is raised to form the space 16, and in this state, the block of the thermosetting resin molding material having the flat surface obtained as described above. 1A is placed on the first mold 2a. Next, as shown in FIG. 6, the second molding die 2b is lowered to close the die, and the block 1A of the thermosetting resin molding material having a flat surface is pressure-compressed to be cured or semi-cured to obtain a resin molded product. Mold 3.
In this case, since the block 1A of the thermosetting resin molding material has a flat surface, air is not entrained between the split mold 2 and the block 1A of the thermosetting resin molding material,
Further, since the block 1A of the thermosetting resin molding material has the plurality of thermosetting resin molding materials 1 stacked and compressed to deaerate the internal air as described above, the air is removed between the thermosetting resin materials 1. Therefore, it is possible to form a high quality resin molded product 3 in which voids are not generated. Further, since the molding by the mold 6 prior to the molding by the split mold 2 is set to such an extent that the curing reaction of the thermosetting resin molding material 1 does not occur, the heat generated by the molding by the split mold 2 is reduced. It has no adverse effect on the curing reaction of the curable resin molding material 1.

Next, as shown in FIG. 7, the second molding die 2b is raised slightly to make the surface of the resin molding 3 and the first molding die 2a.
A small gap is formed between and. Next, as shown in FIG. 8, the opening / closing valve 12 is opened to cover the unsaturated polyester resin, vinyl ester resin, epoxy resin, acrylic resin, or a molding resin made of a mixture of these resins. Is injected into the slight gap between the surface side of the resin molded product 3 and the first molding die 2a from the injection port 8 by the coating material supply device 10, and when the injection of the coating material 4 is completed, it is opened and closed as shown in FIG. Close the valve 12 and perform recompression molding to make a resin molded product 3
The coating layer 5 is formed on the surface side of the.

Then, as shown in FIG. 10, the second mold 2b is formed.
Is raised to open the mold, and in this state, the coated molded product is taken out. In the embodiments shown in the accompanying drawings, an example of a bath is shown as a coated molded product. The coated molded product thus produced has the coating layer 5 formed on the surface of the resin molded product 3, but as described above, a high quality product having no void is manufactured.

In the above molding, the molding conditions for molding the bath include the first molding die 2a and the second molding die 2
In both cases, the mold temperature is 120 ° C. to 130 ° C., and the molding time is about 12 minutes.

[0014]

According to the present invention, as described above, the sheet-shaped thermosetting resin molding material is set between the dies different from the split dies which are set to the extent that the curing reaction does not occur. Laminating and placing the thermosetting resin molding material, and compressing the sheet-shaped thermosetting resin molding material laminated by the mold to obtain a block of the thermosetting resin molding material having a flat surface. Since a block of the thermosetting resin molding material is placed in a split mold and heated or pressed to cure or semi-cure, a coating material is injected into the split mold to form a coated molded article, By using a block of thermosetting resin molding material with a flat surface shape, air is not trapped between the sheet thermosetting resin molding material or between the thermosetting resin molding material and the split mold. Due to involvement It is possible to eliminate the occurrence of id, those capable of producing a high-quality coating moldings.

[Brief description of drawings]

FIG. 1 is an explanatory diagram showing a manufacturing sequence of the present invention.

FIG. 2 is an explanatory view showing a manufacturing sequence of the above.

FIG. 3 is an explanatory view showing the manufacturing sequence of the above.

FIG. 4 is an explanatory view showing the manufacturing sequence of the above.

FIG. 5 is an explanatory view showing the manufacturing sequence of the above.

FIG. 6 is an explanatory view showing the manufacturing sequence of the above.

FIG. 7 is an explanatory view showing the manufacturing sequence of the above.

FIG. 8 is an explanatory view showing the manufacturing sequence of the above.

FIG. 9 is an explanatory view showing the manufacturing sequence of the above.

FIG. 10 is an explanatory view showing the manufacturing sequence of the above.

FIG. 11 is a perspective view of a sheet-shaped thermosetting resin molding material used in the above.

[Explanation of symbols]

 1 Thermosetting Resin Molding Material 1A Block of Thermosetting Resin Molding Material 2 Divided Mold 3 Resin Molded Product 4 Coating Material 5 Coating Layer 6 Mold

─────────────────────────────────────────────────── ─── Continuation of the front page (51) Int.Cl. ⁶ Identification number Internal reference number FI technical display location // B29K 101: 10 B29L 9:00 (72) Inventor Naoto Ikegawa 1048 Kadoma, Kadoma, Osaka Prefecture Matsushita Electric Works Co., Ltd. (72) Inventor Masutani Kobayakawa 1048 Kadoma, Kadoma City, Osaka Prefecture Matsushita Electric Works Co., Ltd. (72) Masami Matsumoto 1048, Kadoma, Kadoma City, Osaka Matsushita Electric Works Co., Ltd. 72) Inventor Shozo Tanaka 5-8 Nishimitabicho, Suita City, Osaka Prefecture Japan Catalysis Resin Technology Laboratory Co., Ltd. (72) Inventor Shigeru Oka 5-8 Nishimitabicho, Suita City, Osaka Prefecture Nippon Catalysis Resin Technology Co., Ltd. In the laboratory

Claims (1)

[Claims] 1. A resin molding product in which a thermosetting resin molding material is heated and pressed by a split mold to be cured or semi-cured, and a coating material is injected into the split mold and heated and pressed again. In the method for molding a coated molded article in which a coating layer is formed on the surface of the sheet-shaped thermosetting resin molding material, the sheet-shaped thermosetting resin molding material is set to such an extent that a curing reaction does not occur, and the sheet-shaped metal sheet A step of stacking and placing a thermosetting resin molding material, a step of compressing the sheet-shaped thermosetting resin molding material laminated by the mold to obtain a block of a thermosetting resin molding material having a flat surface, It is characterized in that the block of the thermosetting resin molding material is arranged in a split mold, and a coating material is injected into the split mold in a state of being heated and pressed to be cured or semi-cured to form a coated molded product. Molding of resin molded products Method.