JP2000071228A - Form with protrusion and recess pattern made of composite molded product and its manufacture - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a novel form durable against repetitive use by providing a light weight, excellent rigidity and toughness. SOLUTION: The form comprises a plate-like portion having a protrusion and recess pattern at least on one side surface and a composite molded product of a sandwiching structure having a porous core layer made of light weight charging particles and curable resin between upper and lower dense skin layers made of fiber reinforced resin as a material for molding the form. In this case, as the structure for constituting the plate-like portion, a sandwiching structure having upper and lower dense skin layers each made of fiber-reinforced resin containing a protrusion and recess part containing a fiber-like material and/or particles having a long diameter of 0.3 to 6 mm on at least one side surface, and a separate film disposed between porous core layers each made of light weight charging particles and curable resin is suitable.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a novel formwork for manufacturing a cement plate with a concave and convex pattern for forming a patterned pattern in which the concave and convex pattern on the wall of a building is continuous vertically and horizontally. . More specifically, it is made of a sandwich-molded composite molded product composed of a skin layer made of fiber-reinforced resin with an uneven pattern on the surface and a porous core layer made of a syntactic foam core. TECHNICAL FIELD The present invention relates to a mold having high rigidity, and relates to a novel mold having a significantly improved number of diversions as compared with a conventional wooden form.

[0002]

2. Description of the Related Art In recent years, there has been a demand for exterior wallboards having a beautiful surface pattern in which the unevenness of the surface is continuous vertically and horizontally at the time of construction due to the tendency of individualization and upgrading. When manufacturing an outer wall plate having a shape, a combination of a sheet-shaped material having a concavo-convex pattern with a urethane resin or the like on a wooden formwork or a plastic made of glass fiber reinforced is used.

[0003] However, in the above-described wooden formwork, the wood used as a material is being protected by the movement of protecting the rainforest on a global scale.
Recently, it has become difficult to obtain. In addition, from the viewpoint of nature protection, the government or local government is moving to restrict its use, and there is concern about future material supply.
Furthermore, the surface condition of a wooden formwork deteriorates after two to three to ten uses, and at present it is disposable, and a sheet-like material such as urethane resin having an uneven pattern has a linear expansion coefficient. Since it is large, it has a problem that it is easily affected by the outside air temperature and the dimensional error increases.

In order to solve these problems, glass fiber reinforced plastics have been proposed. Hand lay-up and resin transfer molding (RTM) methods are generally used as a method of forming a plastic template having a concavo-convex pattern. However, these methods have problems such as a long molding time.

[0005] For this reason, proposals have been made for molds made of new materials in place of wood. For example, Tokiko 4-36
No. 1006, No. 6-315922, No. 7-2
No. 4821 proposes a fiber reinforced resin form having a concave and convex pattern on the surface or a form formed by laminating a thermoplastic resin layer. However, the formwork according to this proposal,
There are many steps for forming a multilayer structure.

In addition, the uneven pattern portion has many problems such as the formation of resin pools, the generation of voids, and the lack of convex portions, and the low glass fiber content, which results in a large linear expansion coefficient and warpage of the template. In order to increase productivity, RT
M method etc. are used, but the point that the HLU fiber content is low in the concavo-convex pattern portion is the same. As the mold used for the RTM, an expensive mold such as an electroforming mold is required, and it takes a long time to manufacture the mold. And it takes a long time to develop products.

[0007]

DISCLOSURE OF THE INVENTION The present invention is economical, replaces a conventional wooden formwork, is lightweight with excellent dimensional accuracy when used, is excellent in rigidity and strength, and has many uses. An object of the present invention is to provide a new mold that can withstand repeated use and a mold for molding the mold at an early stage.

[0008]

Means for Solving the Problems The inventors of the present invention have made intensive studies to solve the above-mentioned problems, and as a result, have found that a syntactic foam containing hollow lightweight particles between a dense skin layer comprising upper and lower fiber reinforced resins. In forming a concavo-convex pattern on the surface layer portion of a composite molded product (for example, described in Japanese Patent Publication No. Hei 7-12613) integrally formed in a sandwich structure sandwiching a porous core layer made of Is filled with a fibrous material and / or particles having a size of 0.3 mm to 6 mm, can solve various problems found in conventional wooden or synthetic resin molds, and is extremely useful. The present invention has been found to provide a mold having a high flexibility, and has reached the present invention.

That is, the mold according to the present invention is a mold having a plate-like portion having an uneven pattern on at least one surface, and the plate-like portion is provided between a dense skin layer made of upper and lower fiber reinforced resins. A sandwich structure having a porous core layer composed of light-filled particles and a cured resin, wherein the uneven pattern portion includes a fibrous material and / or particles having a major axis of 0.3 mm to 6 mm, and the entire mold is integrally formed. And a mold having a plate-like portion having an uneven pattern on at least one surface, wherein the plate-like portion is formed of upper and lower fiber reinforced resins. A sandwich structure composed of a dense skin layer, a porous core layer composed of lightweight filler particles and a cured resin present therebetween, and a separation membrane disposed between each of these layers, and has at least one surface with an uneven pattern The part is the long diameter Contains fibrous materials and / or particles of 0.3 mm to 6 mm, and is formed of a composite molded product in which the entire mold is integrated.

As described above, in the mold of the present invention, the surface layer portion having a concave-convex pattern occupying substantially all or most of the surface layer portion includes a reinforcing short fiber, a surface layer portion made of particles and a cured resin, and a plate-like portion. A porous core (syntactic foam) composed of lightweight filler particles and a cured resin between a dense skin layer of a fiber sheet for reinforcement and a fiber reinforced resin (FRP) composed of a cured resin via a separation membrane if necessary. The greatest feature is that it is a sandwich structure integrally molded so as to sandwich the core) layer. In the mold of the present invention, a reinforcing material may be locally disposed in the porous material.

[0011] The mold of the present invention having such a structure is basically (a) a lower mold for producing the mold of the present invention (hereinafter also referred to as an original mold) during molding. A fibrous material and / or particles having a long diameter of 0.3 mm to 6 mm are spread on the uneven pattern portion on the contact side, and (b) the curable resin and the average particle diameter are 0.01
(C) mixing with light-filled particles of 2 to 2 mm (and / or precursor particles thereof) to prepare a particle-containing resin composition;
The above particle-containing resin composition is supplied between two reinforcing fibrous sheets to form a laminate. (D) Next, the laminate is formed with an irregular pattern on at least one surface for forming a mold. Heat in the mold to cure the curable resin,
It is manufactured by a method of obtaining a mold made of a composite molded article.

In the mold of the present invention, a short fiber having a long diameter of 0.3 mm to 6 mm used for a layer having an uneven pattern portion,
Specific examples of the particles include glass fibers, carbon fibers, silicon carbide fibers, metal fibers and glass beads, ceramic particles, and a mixture of two or more of these. Among them, chopped strands in which glass fibers are cut short, spherical particles made of glass, and pulverized materials are predominantly used.

Specific examples of the reinforcing fibrous sheet material used for the skin layer include glass fiber, carbon fiber, silicon carbide fiber, metal fiber, aramid fiber, polyarylate fiber, high-strength polyethylene fiber, or a mixture thereof.
Mixtures of more than one species can be given. In addition to these fibers, polyester fibers, polyvinyl alcohol fibers, rayon fibers, acetate fibers, natural fibers, mineral fibers, and the like can also be used. Among them, it is preferable to use a high-strength, high-rigidity (high modulus) fiber such as a glass fiber, a carbon fiber, and a para-aramid fiber.

Examples of the form of the reinforcing fibrous sheet include various woven fabrics (plain weave, twill weave, sudare weave, etc.), knitted fabrics, nonwoven fabrics, mats, papers and sheet materials such as rovings which are gathered in one direction and gathered in a layered form. Is used. These may be used alone, or two or more sheet materials may be used in an overlapping manner.

On the other hand, the lightweight filler particles contained in the porous core layer include (a) porous or hollow resin particles thermally expanded during molding, (a) porous or hollow compressible lightweight particles, and (c) porous or hollow particles. It is at least one kind of particles selected from the group consisting of hollow rigid lightweight particles, and preferably has an apparent specific gravity of 0.05 to 0.70 and an average particle size of 0.01 to 2
A monocell or multicell porous or hollow particle having a diameter of mm (however, the value after expansion in the case of the resin particles (a)) is used.

When the resin particles of (a) or the compressible particles of (a) are used as the lightweight filler particles, the rigid lightweight particles are blended so that 50% by weight or more of the lightweight filler particles become the rigid lightweight particles. Is preferable in forming a strong mold.

The thermally expanded foamed resin particles of the above (A)
Before molding, it is a heat-expandable resin particle that contains a substance that expands in volume due to heating and is not yet light in weight. Wake up to become lightweight porous or hollow particles, and by subsequent curing of the curable resin,
It has the property of forming a syntactic foam structure having a lightweight porous structure. The magnification of such volume expansion is
The heating conditions depend not only on the type of the polymer material constituting the resin particles, the film thickness of the particles, but also on the substance contained in the particles and causing a significant volume change by heating, but at least about 10% by heating during molding. Above, preferably about 2
It causes volume expansion of 0% or more, usually 20% to 70 times. The size of the heat-expandable resin particles is preferably such that the average particle size before volume expansion is about 0.001 to 2 mm.

Examples of the above-mentioned heat-expandable resin particles include particles made of a polyacrylonitrile copolymer, a polymethacrylonitrile copolymer, a polyvinylidene chloride copolymer, a polyolefin, a polyphenylene oxide copolymer, or the like. In addition, fine resin particles containing a heat-expandable substance therein may be mentioned, and those containing low-boiling hydrocarbons which expand in volume by being gasified by heating are preferred. Specific examples of such heat-expandable resin particles include "Matsumoto Microsphere" manufactured by Matsumoto Yushi-Seiyaku Co., Ltd. and "Expancel" manufactured by Nobel Corporation.

The compressible particles of the above (b) have a low specific gravity of about 1 to 70% (preferably about 5 to 50%) of the volume due to compressive deformation (elastic deformation or plastic deformation) by pressurization. The typical examples are hollow lightweight particles obtained by previously heating and expanding the above-mentioned heat-expandable resin particles in air or an inert gas, and calcium carbonate or titanium oxide on the surfaces of the expanded hollow particles. Such as hollow lightweight particles coated with a thin rigid component, or porous polypropylene particles.

These compressible particles are one type of non-expandable particles that do not substantially expand in volume when reheated.
It differs from glass balloons used in conventional syntactic foam structures in that they are compressed and deformed by pressure during molding.

Specific examples of such compressible particles include, for example, "Matsumoto Microsphere" manufactured by Matsumoto Yushi Seiyaku Co., Ltd., "Expancel" manufactured by Nobel, and "Eslen Bead" manufactured by Sekisui Chemical Co., Ltd. And the like, which are expanded by heating with steam or heating in air or an inert gas. The size of these compressible particles is in the range of 0.01 to 2 mm, preferably 0.05 to 2 mm in average particle size.

The rigid lightweight particles (c) are fine hollow particles having high rigidity which are hardly deformed even under a pressurized state, and typical examples thereof are known as glass balloons, shirasu balloons, silica balloons and the like. Inorganic hollow fine particles. The size of such rigid particles is 0.01 to 2 m in average particle size.
m, especially those having a range of 0.05 to 2 mm are preferably used.

In the present invention, the resin contained in the skin layer and the core layer of the composite molded article composing the mold and forming these layers is a curable resin, and the resin is cured by curing during molding. And the core layer are integrally formed.

The curable resin used here is a thermosetting resin used for molding a general composite material. Usually, a liquid resin at room temperature is preferably used. Any solid or semi-solid at room temperature can be used as long as it becomes liquid in a heated state during molding. Specific examples of such a curable resin include an epoxy resin, an unsaturated polyester resin, a vinyl ester resin, an acrylic urethane resin, a phenol resin, a polyurethane resin, an acrylic resin, a dicyclopentadiene resin, and a petroleum resin. Among them, epoxy resins, unsaturated polyester resins, vinyl ester resins, phenol resins and the like are preferred curable resins. This curable resin is usually used together with a necessary curing agent or initiator, a curing accelerator, a diluent and the like.

In the present invention, as described above, fine lightweight filler particles are used as a constituent component of the porous core (syntactic foam core) layer. Together with the reinforcing fibrous sheet forming the skin layer, and when the reinforcing fibrous sheet has a large opening (especially when heat-expandable particles are used), the light-filled particles are coated on the surface of the molded article. It can also seep out. In such a case, it is preferable to dispose the separation membrane inside the upper and lower reinforcing fibrous sheets so as to be in contact with the layer of the particle-containing resin composition.

The separation membrane is a thin sheet having a property of allowing the curable resin to pass therethrough but preventing the passage of the lightweight filler particles. The separation membrane is formed by a reinforcing fibrous sheet and a particle-containing resin composition layer. By molding with intervening therebetween, it is possible to prevent the light-weight filler particles from oozing into the surface layer as described above during molding.

As such a separation membrane, a fibrous sheet and / or a porous sheet having a small opening is used.
As the fibrous sheet for the separation membrane, for example, a woven fabric, a knitted fabric, a braid, a nonwoven fabric, a paper, etc., made of various natural fibers, synthetic fibers, inorganic fibers, and the like are used. The porous sheet is a sheet or a film having continuous air holes, and is a foam sheet of polyurethane, polypropylene, polystyrene, or the like, or a porous membrane of polyethylene, polypropylene, polysulfone, or the like manufactured by a stretching, extraction, or coagulation method or the like. .

The aperture of these separation membranes is appropriately selected according to the size of the lightweight filler particles. In addition, as the material of the separation membrane, a material having elasticity can be selected so that it can be easily adjusted to the shape of the molded product. A part of the separation membrane may be made of a material that does not allow the hardening resin to pass through. For example, a part made of a material having a separating function and a part made of a material having a different function are joined together, and a part of a sheet having a separating function is previously sealed with a resin or the like. What was processed, the fibrous sheet is a polypropylene fiber sheet, the fusible part of which is partially fused by heat treatment and some openings are crushed, and a part of the material having a separating function A non-porous film may be attached.

It is to be noted that a fibrous sheet having a small opening made of glass fiber, carbon fiber, aramid fiber, or the like, which itself has a function as a reinforcing material, can be used as the separation membrane. In this case, the fibrous sheet can be used as a reinforcing fibrous sheet and a separation membrane.

However, when the reinforcing fibrous sheet and the separation membrane are separately disposed, the aperture of the reinforcing fibrous sheet can be freely selected. For example, a unidirectional fiber array prepreg or a three-dimensional weave can be used. Knitted preforms and the like can also be used, and it is preferable because materials can be arbitrarily selected according to the appearance and characteristics required for the surface of the formwork.

According to the study of the present inventors, for example, a long-fiber nonwoven fabric with a small opening, which is commercially available under a trade name such as "Unicell", is excellent in many aspects such as separation function and handleability. It was found to be particularly suitable.

On the other hand, the lightweight filler particles (and / or precursor particles thereof) used in the production of the mold of the present invention are:
As described above, it is at least one kind of particles selected from the group consisting of heat-expandable resin particles, compressible particles, and rigid lightweight particles. That is, each of these particles may be used alone, and may be used in the form of a mixture of heat-expandable resin particles and rigid lightweight particles or a mixture of compressible particles and rigid lightweight particles, as described above. As described above, it is preferable that rigid lightweight particles are present in the core layer, and it is preferable to use the particles alone or mixed particles of 50% by weight or more of the rigid lightweight particles.

The amount of the lightweight filler particles used in the production of the mold of the present invention is such that the total amount of the lightweight filler particles (after expansion in the case of the heat-expandable resin particles) in the core layer of the mold which is a composite molded product is: It is preferable to use an amount in the range of 20 to 80% by volume based on the sum of the total amount of the curable resin and the lightweight filler particles in the core layer. If the use amount of the lightweight filler particles is less than 20% by volume, the effect of reducing the specific gravity of the mold according to the present invention becomes small, which is not preferable. On the other hand, when it exceeds 80% by volume, although a further reduction in weight is achieved,
It is not preferable because the filling condition of the curable resin in the core layer is not good, causing problems such as cracks, and lowering the rigidity and strength of the mold. A more preferred usage of the lightweight filler particles to obtain a mold with suitable properties is in the range of 30-70% by volume.

In the production of the mold of the present invention, various components may be added together with the above-mentioned lightweight filler particles and the curable resin to improve the mechanical properties, flame retardancy, heat resistance or moldability of the molded product. It is also possible to use additives in combination. Examples of these additives include milled glass, clay, kaolin, mica, calcium carbonate, calcium sulfate, silica, alumina, aluminum hydroxide hydrate, various flame retardants, various pigments, ultraviolet absorbers, internal mold release agents And the like. Other examples of these additives include used resin molded products and finely pulverized products from FRP.

A first method for producing a mold made of the composite molded article of the present invention using such a material is as follows: heat-expandable particles (or rigid light-weight particles) as precursor particles thereof as light-weight filler particles; A mixture with)
(A) When molding, the long diameter of the irregular pattern on the lower side of the original mold is 0.
3 mm to 6 mm of fibrous material and / or particles
(B) A curable resin and the above lightweight filler particles are mixed to prepare a particle-containing resin composition, and (c) upper and lower two reinforcing fibrous sheets cut to predetermined dimensions (and 2 Two separation membranes), and the above-mentioned resin composition containing particles is supplied between the upper and lower two reinforcing fiber sheets so as to form a layer having a substantially uniform thickness, and the reinforcing fiber sheet / (separation membrane) / A laminate composed of the particle-containing resin composition / (separation membrane) / fibrous sheet for reinforcement is formed, and (d) this laminate is placed in an original mold for forming a predetermined mold (the lower mold is the above (a) (E) After closing the original mold, heat to expand the heat-expandable particles in the particle-containing resin composition, thereby utilizing the pressure generated in the original mold. The curable resin is penetrated into the upper and lower reinforcing fibrous sheets, part of which is brought to the surface, and (f) heating and And / or by curing the curable resin present in the original mold by the reaction heat of the resin and completing the solidification, the dense skin layer made of fiber reinforced resin and the porous core layer made of syntactic foam are formed. This is a method for producing a desired lightweight and high-rigidity formwork as an integrated composite molded product.

The second method is to use non-thermally expandable compressible particles as lightweight filler particles. The compressible particles are already expanded hollow particles, do not expand due to heating, and are reduced in volume by being pressurized into a compressed state. According to this method, (a) fibrous materials and / or particles having a long diameter of 0.3 mm to 6 mm are spread over the uneven pattern portion on the lower side of the original mold during molding, and (b) the curable resin and the compressibility The resin composition is prepared by mixing particles with the particles, and (c) two upper and lower reinforcing fibrous sheets cut to a predetermined size (and 2
Two separation membranes), and the particle-containing resin composition is supplied between the two reinforcing fiber sheets so as to form a layer having a substantially uniform thickness, and the reinforcing fiber sheet / (separation membrane) /
A laminate comprising a resin composition containing particles / (separation membrane) / fibrous sheet for reinforcement was prepared. (D) This laminate was set in a predetermined mold for forming a mold, and (e) a mold was formed. The frame is closed to be in a compressed state, and the curable resin in the particle-containing resin composition is penetrated into the upper and lower reinforcing fibrous sheets, a part of which is brought to the surface, and (f) heat and / or heat of reaction of the resin. By curing the curable resin in the original formwork and completing the solidification, a dense skin layer made of a fiber reinforced resin having a skin layer having a fine uneven pattern reinforced with a fiber and a porosity made of a syntactic foam This is a method for producing a desired lightweight and high-rigidity formwork by forming a composite molded article in which a high quality core layer is integrated.

Further, the third production method is a method in which rigid lightweight particles are used as lightweight filler particles. As described above, this rigid lightweight particle is a hollow particle having high rigidity that does not essentially cause a volume change upon heating or pressurization, and inorganic hollow particles such as commonly used glass balloons and shirasu balloons are preferable. used.

In this case, except that the pressure does not essentially change the volume (compression and recovery), the mold can be manufactured substantially in accordance with the above-described method using the compressible particles.

The above three production methods are typical examples, and a resin composition containing particles is prepared in a state where two or more of these various lightweight filler particles are mixed. It is, of course, possible to produce a mold made of a composite molded product having a sandwich structure.In particular, the combined use of expandable particles and rigid lightweight particles, and the use of compressible particles and rigid lightweight particles, This is an extremely effective method for maximizing the physical properties of the obtained mold.

[0040]

BEST MODE FOR CARRYING OUT THE INVENTION The mold of the present invention comprises only a surface portion having an uneven pattern on at least one surface and a plate portion having a sandwich structure having a porous core layer.

The thickness of the plate-like portion is usually 2 to 30 mm.
Is appropriate, and the thickness of the porous core layer in the sandwich structure constituting the plate-like portion is in the range of 1/2 to 50/1 with respect to the total thickness of the skin layer; The specific gravity of the porous core layer in the plate-like portion is 0.3 to
0.7, and the specific gravity of the plate-like portion is in the range of 0.5 to 1.2. It is preferable for forming a frame.

The dimension of the plate-shaped portion is, for example, in the case of a siding board form, the length in the vertical direction is 1000 to 60.
00mm, horizontal length is 1/6 to 1 of vertical length
/ 2 and a thickness of 4 to 20 mm are appropriate, but may be appropriately changed depending on the use of the formwork.

Further, a reinforcing material may be locally included in the core portion of the plate-shaped portion to improve resistance to bending. As such a reinforcing material, a braid made of glass fiber is preferable, and the braid is usually arranged at an appropriate interval.

If the porous core layer is exposed on the end face of the mold, if there is a concern about peeling strength or the like, the end face of the mold is preferably made of a fiber-reinforced resin or resin alone.

[0045]

[Example 1] (1) Preparation of molding die Length in longitudinal direction = 3,210 mm, length in lateral direction = 1,2
Aluminum mold having a cavity in which a flat plate having a thickness of 00 mm and a height of 12 mm can be obtained, and a cement-based board and a symmetrical concavo-convex pattern model (silicone type) = plate portion 3.5
mm and an uneven portion of 4 mm were prepared.

(2) Preparation of Fiber Sheet for Reinforcement and Separation Membrane A glass fiber chopped strand mat (Glaslon CM6 manufactured by Asahi Fiberglass) was used as a fiber sheet for reinforcement.
00 ", basis weight 600 g / m ² , 3 mm length chopped strand (manufactured by Asahi Fiberglass; CS03JA)
D) and milled fiber (made by Asahi Fiberglass;
MF20MH2-20) at a volume ratio of 2: 1 polyester nonwoven fabric (UniCel® manufactured as a filling material and the separation membrane was mixed with "UniCel® BT0807W" was prepared basis weight 40 g / m ^2).

(3) Preparation of Resin Composition Containing Particles Epoxy resin (“Epiclon 840” manufactured by Dainippon Ink and Chemicals) as a curable resin and 1,3 BAC as a curing agent
[Mitsubishi Gas Chemical; 1,3-BIS (AMINOMETHYL) CYCLOHEXANE]
Using a mixture of 100/19 (weight ratio) and heat-expandable (expandable) resin particles as lightweight filler particles ("Matsumoto Microsphere TEM-8" manufactured by Matsumoto Yushi Pharmaceutical Co., Ltd.)
And a mixed system of glass balloons ("Glass Bubbles K-37" manufactured by Sumitomo 3M) which are rigid and lightweight particles (weight ratio of 1 /
5) was used. The curable resin and the light-filled particle mixture were mixed at a weight ratio of 100/23 to prepare a slurry-like particle-containing resin composition.

The specific gravity of the heat-expandable resin particles before thermal expansion is 1.06, but it expands about 10 times in volume ratio due to the curing reaction of the epoxy resin at the time of molding, and the specific gravity after molding is about 0. .1. On the other hand, the specific gravity of the rigid lightweight particles is 0.3
7

(4) Molding of a master for manufacturing a siding board A cement board and a symmetrical concavo-convex model (silicon sheet) were laid on the above-mentioned aluminum mold, and 110 ° C.
2 liters of a previously prepared filling material (a mixture of glass chopped strands and glass milled fiber) was filled into the concave portion of the concave-convex pattern portion of the mold heated by the hot plate press. A reinforcing fibrous sheet (chopped strand mat) and a separation membrane (polyester non-woven fabric) are set, and the particle-containing resin composition heated to 65 ° C. is supplied thereon so as to spread over the entire flat surface of the mold.
After stacking another separation membrane on it, another reinforcing fiber sheet (chopped strand mat)
And a cut chopped strand mat for reinforcing the thick part is set to a flat state, set in a hot plate press previously heated to 110 ° C., and the mold is closed to 10 kg / c.
A pressure of m ² was applied and held for 15 minutes.

During this time, the heat generated by the heat transfer from the mold and the reaction of the resin causes the volume expansion of the heat-expandable resin particles in the mold, and then the curing reaction of the curable resin proceeds and the original mold expands. The molding of was completed.

The original mold made of the obtained composite molded article has the same shape as the concavo-convex pattern of the cement-based board.
3.5 mm, the thickness of the plate-shaped portion (plane portion) was 4.5 mm, and there was no warpage.

(5) Forming a mold for manufacturing a siding board The original mold formed in (4) was laid on an aluminum mold so that the uneven pattern surface was up, and was heated in advance by a hot plate press at 110 ° C. The concave portion of the concave-convex pattern portion of the mold was filled with 2 liters of a previously prepared filling material (a mixture of glass chopped strand and glass milled fiber) in volume. A reinforcing fibrous sheet (chopped strand mat) and a separation membrane (polyester nonwoven fabric) are set, and the above-mentioned particle-containing resin composition heated to 65 ° C. is supplied thereon so as to be spread over the entire flat portion of the mold. Another one on top
After stacking two separation membranes, another reinforcing fibrous sheet (chopped strand mat) and a cut chopped strand mat for reinforcing the thick-walled portion are set to a flat state, and heated to 110 ° C. in advance. The mold was set in the hot plate press, and the mold was closed, a pressure of 10 kg / cm ² was applied, and the mixture was held for 15 minutes.

During this time, the heat generated by the heat transfer from the mold and the reaction of the resin causes the volume expansion of the heat-expandable resin particles in the mold, and then the curing reaction of the curable resin proceeds to form the mold. The molding was completed.

The resulting template had the same concavo-convex pattern as the silicone model, and had no defects on the concavo-convex surface, and the shape was faithfully transferred. In addition, a template having a specific gravity of 1.03 and being lightweight and having no warpage was obtained.

The linear expansion coefficient of this template was smaller than that of the hand lay-up product, and the flat part and the convex part were almost the same. Example 1 Hand lay-up template Flat plate portion 18.7 × 10 ^-6 26.8 × 10 ^-6 Convex portion 20.8 × 10 ^-6 59.6 × 10 ^-6 This template was heated in an oven at 80 ° C. As a result, the template obtained in this example did not warp, and the hand layup-made template significantly warped.

Claims (6)

[Claims] 1. A mold having a plate-like portion having an uneven pattern on at least one surface, wherein the plate-like portion is formed by a light-filled particle and a cured resin between a dense skin layer composed of upper and lower fiber-reinforced resins. A sandwich structure having a porous core layer, wherein the concave-convex pattern portion includes a fibrous material and / or particles having a long diameter of 0.3 mm to 6 mm, and is constituted by a composite molded article in which the entire mold is integrated. Formwork characterized by being. 2. A mold having a plate-like portion having an uneven pattern on at least one surface, the plate-like portion being a dense skin layer comprising upper and lower fiber-reinforced resins, lightweight filler particles and a cured resin existing between them. And a sandwich structure composed of a porous core layer consisting of: and a separation membrane disposed between each of these layers, and at least one of the concavo-convex pattern portions on one surface has a major axis of 0.3 mm to 6 mm in a fibrous material and / or Alternatively, a mold containing particles and constituted by a composite molded product in which the entire mold is integrated. 3. The method according to claim 1, wherein (a) the curable resin has an average particle size of 0.1.
A resin particle-containing resin composition is prepared by mixing lightweight filler particles of 1 to 2 mm and / or precursor particles thereof, and (b) the particle-containing resin composition is supplied in a layered manner between upper and lower reinforcing fibrous sheets. Then, a laminate consisting of a reinforcing fibrous sheet / particle-containing resin composition / reinforcing fibrous sheet is formed. (C) Then, the above-mentioned laminate is subjected to mold forming after or without pressing. (D) is heated in the original mold, and cured in a state where the curable resin is infiltrated into the reinforcing fibrous sheet to form a composite molded article mold. A method for producing a formwork, comprising: 4. A curable resin having an average particle size of 0.1%.
A light-filled particle having a particle size of 1 to 2 mm and / or its precursor particles are mixed to prepare a particle-containing resin composition, and (b) two reinforcing fibrous sheets and two separation membranes are arranged. The above-mentioned particle-containing resin composition is supplied in the form of a layer inside, and a reinforcing fibrous sheet / separation membrane / particle-containing resin composition /
A laminate consisting of a separation membrane / fibrous sheet for reinforcement,
(C) Next, after the above-mentioned laminate is or is not pressurized, it is set in an original form for forming a form, and (d)
A method for producing a mold, characterized in that the mold is heated in an original mold and cured in a state in which a curable resin is infiltrated into a reinforcing fibrous sheet to form a mold formed of a composite molded product. 5. (a) Filling a fibrous shape and / or a particle having a long diameter of 0.3 to 6 mm into a lower mold having a concave and convex pattern,
(B) a curable resin and lightweight filler particles having an average particle size of 0.01 to 2 mm and / or a precursor particle thereof are mixed to prepare a particle-containing resin composition, and (c) two reinforcing fibrous sheets. And two separation membranes are arranged, and the above-mentioned particle-containing resin composition is supplied in a layer form inside the separation membrane to form a reinforcing fiber sheet / separation membrane / particle-containing resin composition / separation membrane / reinforced fiber (D) Then, the above-mentioned laminate is set in an original mold for forming a mold after or without pressurizing, and (e) heated in the original mold. And curing the resin while the curable resin is infiltrated into the reinforcing fibrous sheet to form a mold comprising a composite molded article. 6. A mold according to claim 1, wherein the mold according to claim 1 or 2 is manufactured by the method according to claim 3 using the mold according to claim 1. Production method.