Fiber-reinforced plastic molded article, its production method and a molding mold using that method

• US 6,863,973 B2
• Filed: 10/15/2001
• Issued: 03/08/2005
• Est. Priority Date: 04/12/2001
• Status: Expired due to Fees

• Current Assignee: Dainippon Ink and Chemicals Incorporated
• Original Assignee: Dainippon Ink and Chemicals Incorporated
• Inventors: Tomokuni, Hidehiko, Shibata, Ou
• Primary Examiner(s): Ahmed, Sheeba
• Application Number:
  US09/976,036
• Publication Number:
  US 20030035961A1
• Time in Patent Office: 1,240 Days
• Field of Search: 428/323, 428/330, 428/411.1, 428/413, 428/414, 428/423.1, 428/480, 428/500
• US Class Current: 428/323
• CPC Class Codes: B29C 37/0032 the coating being applied upon the mould surface before introducing the moulding compound, e.g. applying a gelcoat B29C44/14 and B29C44/32 take precedence
• CPC Class Codes: B29C 70/086 and with one or more layers of pure plastics material, e.g. foam layers applying a non-preformed coating, e.g. a gel-coat, B29C37/0025; with foam blocks B29C70/86
• CPC Class Codes: B29K 2105/06 containing reinforcements, fillers or inserts
• CPC Class Codes: Y10T 428/25 Web or sheet containing structurally defined element or component and including a second component containing structurally defined particles
• CPC Class Codes: Y10T 428/258 Alkali metal or alkaline earth metal or compound thereof
• CPC Class Codes: Y10T 428/31511 Of epoxy ether
• CPC Class Codes: Y10T 428/31515 As intermediate layer
• CPC Class Codes: Y10T 428/31551 Of polyamidoester [polyurethane, polyisocyanate, polycarbamate, etc.]
• CPC Class Codes: Y10T 428/31786 Of polyester [e.g., alkyd, etc.]
• CPC Class Codes: Y10T 428/31855 Of addition polymer from unsaturated monomers

Abstract

The present invention relates to a fiber-reinforced plastic molded article including a surface layer (A) composed of a polymer material, an intermediate layer (B) and a fiber-reinforced plastic layer (C); wherein (1) said intermediate layer (B) is composed of the cured product of an intermediate layer composition comprising a curable resin composition including a polymerizable unsaturated monomer and a polymerization curable unsaturated resin, a filler and a thixotropic agent, (2) said curable resin composition is able to form a casting plate having tensile elongation percentage of 2 to 50% and Barcol hardness (B value) of 50 or more by its curing, (3) the content of said filler is 30 to 150 parts by weight relative to 100 parts by weight of curable resin composition, and (4) the content of said thixotropic agent is 1 to 4 parts by weight relative to 100 parts by weight of curable resin composition.

Claims

1. A fiber-reinforced plastic molded article including a surface layer (A) containing a polymer material, an intermediate layer (B), and a fiber-reinforced plastic layer (C), wherein

(1) said intermediate layer (B) is composed of a cured product of an intermediate layer composition comprising a curable resin composition including a polymerizable unsaturated monomer and a polymerization curable unsaturated resin, a filler, and a thixotropic agent,

(2) said curable resin composition is able to form a casting plate having a tensile elongation percentage of 3 to 50% and a Barcol hardness (B value) of 50 or more by its curing,

(3) the content of said filler is 30 to 150 parts by weight relative to 100 parts by weight of the curable resin composition, and said filler contains a hollow filler having a mean particle size of 5 to 200 μ

m, and

(4) the content of said thixotropic agent is 1 to 4 parts by weight relative to 100 parts by weight of the curable resin composition.

2. A fiber-reinforced plastic molded article according to claim 1, wherein said curable resin composition has a gelation time of 10 to 30 minutes and a viscosity of 20 to 40 poise.

3. A fiber-reinforced plastic molded article according to claim 1, wherein said curable resin composition has a gelation time of 3 to 8 minutes and a viscosity of more than 40 but no more than 100 poise.

4. A fiber-reinforced plastic molded article according to claim 1, wherein said polymerization curable unsaturated resin is at least one type selected from a group including epoxy(meth)acrylate resin, urethane(meth)acrylate resin, and unsaturated polyester.

5. A fiber-reinforced plastic molded article according to claim 1, wherein said curable resin composition is able to form a casting plate having a tensile elongation percentage of 3 to 10% and a Barcol hardness (B value) of 50 to 95 by its curing.

6. A fiber-reinforced plastic molded article according to claim 1, wherein said curable resin composition is able to form a casting plate having a Heat Deflection temperature of 60°

C. or more, a tensile strength of 10 MPa or more, and a Barcol hardness (A value) of 30 or more.

7. A fiber-reinforced plastic molded article according to claim 1, wherein said filler is calcium carbonate powder.

8. A fiber-reinforced plastic molded article according to claim 1, wherein said surface layer (A) is composed of a cured product of a gelcoat resin.

9. A molding mold equipped with the fiber-reinforced plastic molded article according to claim 1.