Composite body and method for manufacturing the same

Abstract

To solve the problem that in order to enhance weather resistance of a resin molding, a coating film having high weather resistance is formed on the surface of the resin molding and a composite body is formed, but in the method for forming the coating film on the surface of the resin molding, a manufacturing process becomes complicated, and productivity is lowered, and to improve weather resistance and productivity of a composite body.SOLUTION: A composite body has a resin molding, and a sheet covering a part of all of the surface of the resin molding, wherein the resin molding has a resin cured product and one or more fibers, the sheet has a base material layer and a coating layer positioned on one surface of the base material layer, and the base material layer is positioned closer to the resin molding than the coating layer.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to a composite body including a resin molded body and a sheet, and also to a method for producing the composite body. [Background technology]

[0002] In recent years, resin molded bodies are sometimes used as structural materials such as building materials instead of wood. For example, as railway sleepers, resin molded sleepers are sometimes used instead of wooden sleepers and concrete sleepers. Resin molded bodies generally have the characteristics of being lightweight yet having high mechanical strength.

[0003] As an example of a resin molded product, the following Patent Document 1 discloses a long-fiber-reinforced foam molded product including a cured product of a foamable resin composition and a fiber bundle formed by aligning a plurality of long-fiber reinforcing materials in one direction. The long-fiber-reinforced foam molded product can be produced by a production method including the steps of impregnating a long-fiber bundle with a foamable resin composition to obtain a resin-impregnated fiber bundle, arranging a porous sheet on the surface of the resin-impregnated fiber bundle, and passing the resin-impregnated fiber bundle together with the porous sheet through a molding passage to foam and cure the foamable resin composition. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Patent Publication No. 2022-026706 Summary of the Invention [Problem to be solved by the invention]

[0005] In the conventional resin molded body, it is sometimes impossible to sufficiently improve weather resistance. Specifically, when the resin molded body is irradiated with light for a long period of time (for example, 500 hours), color unevenness may occur on the surface of the resin molded body, or fibers in the resin molded body may become exposed. When color unevenness occurs on the surface of the resin molded body, there is a problem that the quality of the appearance of the resin molded body deteriorates. In addition, when fibers in the resin molded body are exposed, there is a problem that the mechanical strength of the resin molded body decreases.

[0006] In order to improve the weather resistance of a conventional resin molded body, there is a method of forming a coating film having high weather resistance on the surface of the resin molded body to form a composite body. However, the method of forming a coating film on the surface of the resin molded body has a problem that the manufacturing process becomes complicated and the productivity decreases.

[0007] An object of the present invention is to provide a composite having excellent weather resistance and excellent productivity. It is also an object of the present invention to provide a method for producing the composite. [Means for solving the problem]

[0008] The present specification discloses the following composites and methods for producing the composites. <1> A resin molded body and a sheet covering a part or all of a surface of the resin molded body, The resin molded body has a cured resin and one or more fibers, The sheet has a base layer and a coating layer located on one surface of the base layer, The composite body, wherein the base material layer is located closer to the resin molded body than the coating layer. <2> The resin molding includes two or more fibers, The two or more fibers are parallel to each other, The sheet is located on a part or all of a surface of the resin molded body parallel to the longitudinal direction of the fibers. <1> The complex according to claim 1, <3> The resin molded body has a polygonal columnar shape, the fibers included in the resin molding extend from one end surface of the resin molding to the other end surface of the resin molding, The sheet is located on a part or all of a side surface of the resin molded body. <2> The complex according to claim 1, <4> The substrate layer includes fibers. <1> ~ <3> 2. The complex according to claim 1 , <5> The substrate layer is a glass fiber mat, a glass fiber cloth or a nonwoven fabric. <1> ~ <4> 2. The complex according to claim 1 ,

[0009] <6> placing the sheet in a mold; filling the mold with the fibers and a resin composition; curing the resin composition in the mold to form a composite; having <1> ~ <5> 13. A method for producing the complex according to any one of claims 1 to 12. <7> The fiber includes two or more long fibers. A step of supplying a resin composition to the fiber bundle while advancing the fiber bundle in the length direction of the fiber bundle, in which the two or more fibers are aligned in one direction; impregnating the fiber bundle with the supplied resin composition to obtain a resin-impregnated fiber bundle; placing the sheet on a surface of the resin-impregnated fiber bundle; passing the resin-impregnated fiber bundle together with the sheet through a molding passage to cure the resin composition into a continuous composite; cutting the continuous composite to a desired length; having <1> ~ <6> 13. A method for producing the complex according to any one of claims 1 to 12. <8> A step of cutting the continuous composite into a desired length and then forming a coating film on the cut surface of the composite. <7> A method for producing the complex described above. Effect of the Invention

[0010] The composite according to the present invention includes a resin molded body and a sheet disposed on the surface of the resin molded body. In the composite according to the present invention, the resin molded body includes fibers and a cured product of a resin composition. In the composite according to the present invention, the sheet has a base layer and a coating layer disposed on the surface of the base layer, and the sheet is laminated on the surface of the resin molded body from the base layer side of the sheet. Since the composite according to the present invention has the above configuration, it has excellent weather resistance and excellent productivity. [Brief description of the drawings]

[0011] [Figure 1] 1A is a perspective view that illustrates a composite according to a first embodiment of the present invention, and FIG. 1B is a cross-sectional view that illustrates the composite. [Diagram 2] FIG. 2 is a diagram for explaining a method for producing a composite (continuous production method) according to the first embodiment of the present invention. [Diagram 3] FIG. 1 is a cross-sectional view that typically shows a molding passage in a manufacturing method (continuous manufacturing method) for a composite body according to a first embodiment of the present invention. [Figure 4] FIG. 4 is a cross-sectional view that illustrates a composite according to a second embodiment of the present invention. [Diagram 5] FIG. 11 is a cross-sectional view that illustrates a composite according to a third embodiment of the present invention. [Figure 6] FIG. 11 is a cross-sectional view that illustrates a composite according to a fourth embodiment of the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0012] The present invention will be described in detail below.

[0013] The composite according to the present invention includes a resin molded body and a sheet disposed on a surface of the resin molded body. In the composite according to the present invention, the resin molded body includes fibers and a cured product of a resin composition. In the composite according to the present invention, the sheet has a substrate layer and a coating layer disposed on a surface of the substrate layer, and the sheet is laminated on the surface of the resin molded body from the substrate side of the sheet. That is, the composite body according to the present invention comprises a resin molded body and a sheet covering a part or the entirety of the surface of the resin molded body.

[0014] The composite according to the present invention has the above-mentioned configuration, and therefore has excellent weather resistance. Specifically, the composite according to the present invention has the above-mentioned configuration, and therefore even when the composite is irradiated with light for a long period of time (for example, 500 hours), the occurrence of color unevenness on the surface of the composite can be suppressed. As a result, the quality of the appearance of the composite can be maintained. In addition, the composite according to the present invention has the above-mentioned configuration, and therefore even when the composite is irradiated with light for a long period of time (for example, 500 hours), the exposure of fibers in the composite (particularly, the resin molded body) can be suppressed. As a result, the mechanical strength of the composite can be maintained. The composite according to the present invention has the above-mentioned configuration, and therefore even when the resin molded body (cured product of the resin composition) contains a resin with relatively low weather resistance (for example, a urethane resin), the weather resistance of the composite can be improved.

[0015] Furthermore, since the composite according to the present invention has the above-mentioned configuration, it has excellent productivity.

[0016] Hereinafter, specific embodiments of the present invention will be described with reference to the drawings. Note that in the following drawings, the size, thickness, shape, etc. may differ from the actual size, thickness, shape, etc. for convenience of illustration.

[0017] (First embodiment) Fig. 1(a) is a perspective view showing a composite according to a first embodiment of the present invention, and Fig. 1(b) is a cross-sectional view showing the composite along line II in Fig. 1(a).

[0018] 1(a) and (b) includes a resin molded body 9 and a sheet 8 arranged on the surface of the resin molded body 9. In the composite 10, the resin molded body 9 includes fibers 6 and a cured product of a resin composition (cured resin product) 5X. In the composite 10, the sheet 8 includes a base layer 8A and a coating layer 8B arranged on a surface (one side) of the base layer 8A, and the sheet 8 is laminated on the surface of the resin molded body 9 from the base layer 8A side of the sheet 8. That is, the composite 10 comprises a resin molded body 9 and a sheet 8 located on the surface of the resin molded body 9, the sheet 8 having a base material layer 8A and a coating layer 8B located on one side of the base material layer 8A, and in the state of the composite 10, the base material layer 8A is located closer to the resin molded body 9 than the coating layer 8B.

[0019] The composite 10 and the resin molded body 9 are in the shape of a quadrangular prism. The composite 10 and the resin molded body 9 are in the shape of a rectangular parallelepiped with one side being longer in a side view. The composite 10 and the resin molded body 9 have end faces and side faces. Specifically, the composite 10 and the resin molded body 9 have two end faces located at both ends in the length direction and four side faces connecting the two end faces. The resin molded body 9 has, as end faces, a face 9b and a face congruent and parallel to the face 9b (a face hidden in FIG. 1(a)). The resin molded body 9 has, as side faces, faces other than the bottom face (a face 9b and a face congruent and parallel to the face 9b). The resin molded body 9 has, as side faces, a face 9a, a face parallel to the face 9a (a face hidden in FIG. 1(a)), a face 9c, and a face parallel to the face 9c (a face hidden in FIG. 1(a)). The composite body 10 may be used with one end face facing downward, or with one side face facing downward.

[0020] In the composite 10, the sheet 8 is disposed on all surfaces of the resin molded body 9. That is, in the composite 10, the sheet 8 is located on all end faces and side faces of the resin molded body 9.

[0021] In the composite 10, the fibers 6 in the resin molded body 9 include fiber bundles. In the composite 10, the fibers 6 in the resin molded body 9 include two or more long fibers. In the composite 10, the fibers 6 (two or more long fibers) are aligned in one direction. That is, the resin molded body 9 has fiber bundles extending in the length direction (direction from one end face to the other end face).

[0022] In the composite 10, the length direction of the fibers 6 (fiber bundles) in the resin molded body 9 is parallel to the side surfaces of the resin molded body 9 (surface 9a, a surface congruent and parallel to surface 9a, surface 9c, and a surface congruent and parallel to surface 9c). The fibers 6 (fiber bundles) are included in the resin molded body 9 so that the resin molded body 9 has side surfaces parallel to the length direction of the fibers 6 (fiber bundles) (surface 9a, a surface congruent and parallel to surface 9a, surface 9c, and a surface congruent and parallel to surface 9c). That is, in the composite 10, the sheet 8 is located on the surface of the surface (the side surface of the resin molded body 9) parallel to the length direction of the fibers 6 (fiber bundles) in the resin molded body 9.

[0023] <Resin molded body> The resin molded body 9 has two or more fibers 6 and a cured resin material 5X. That is, the resin molded body 9 has the cured resin material 5X and the fibers 6 present in the cured resin material 5X. The fibers 6 may be a bundle of two or more long fibers (fiber bundle), may be short fibers, or may be a mixture of long fibers and short fibers. When the resin molded body 9 contains fiber bundles, the cured resin 5X is impregnated into the gaps between the fibers of the fiber bundles.

[0024] The resin molded body 9 in this embodiment has a rectangular parallelepiped shape, but the present invention is not limited thereto. The resin molded body 9 may have a columnar shape or a spherical shape. The resin molded body 9 is preferably columnar. The resin molded body 9 may be cylindrical or polygonal prism-shaped. From the viewpoint of further increasing the mechanical strength of the composite body 10, the resin molded body 9 is preferably polygonal prism-shaped. The resin molded body 9 may be triangular prism-shaped, quadrangular prism-shaped, pentagonal prism-shaped, or octagonal prism-shaped. The resin molded body may be cubic or rectangular parallelepiped-shaped.

[0025] The size of the resin molded body is not particularly limited and can be appropriately selected depending on the application of the composite and the length of the fibers in the resin molded body.

[0026] <Fiber> The fibers 6 in the resin molded body 9 include short fibers and long fibers. The fibers 6 may be short fibers or long fibers. The fibers 6 may contain short fibers and long fibers. The long fibers have an average fiber length of, for example, 50 mm or more. The short fibers have an average fiber length of, for example, 2 mm or more and less than 50 mm.

[0027] From the viewpoint of further increasing the mechanical strength of the composite 10, the fiber 6 preferably contains long fibers, and more preferably contains reinforcing long fibers. The reinforcing long fibers are reinforcing fibers and long fibers. The reinforcing fibers are fibrous materials having a certain strength. Examples of reinforcing fibers known include carbon fibers, glass fibers, and aramid fibers. The reinforcing long fibers may be a reinforcing long fiber sheet.

[0028] Examples of the reinforcing long fibers include long carbon fibers, long glass fibers, long aramid fibers, polyester fibers, polyamide fibers, long reinforcing fibers, etc. Only one type of reinforcing long fiber may be used, or two or more types may be used in combination.

[0029] The reinforcing long fibers are preferably long glass fibers from the viewpoint of further increasing the mechanical strength of the composite 10. Long glass fibers are fibrous materials formed by melting and drawing glass into fibers.

[0030] From the viewpoint of further increasing the mechanical strength of the composite 10, the fiber length of the reinforcing long fibers is preferably 50 mm or more, more preferably 70 mm or more. The reinforcing long fibers can be cut to a desired size after pultrusion molding, and the fiber length of the reinforcing long fibers can be appropriately changed depending on the cutting length, so that the upper limit of the fiber length of the reinforcing long fibers is not particularly limited. From the viewpoint of increasing the dimensional accuracy, the fiber length of the reinforcing long fibers may be 10 m or less. Even if the fiber length of the reinforcing long fibers is long, the reinforcing long fibers can be made less likely to be cut or entangled by impregnating the reinforcing long fibers with a composition containing components other than the reinforcing long fibers. The resin molded body 9 can be molded by pultrusion molding even if the blending ratio of the reinforcing long fibers is increased.

[0031] The fiber length of the reinforcing long fibers can be measured by using image analysis such as microscope photography of the reinforcing long fibers themselves or the reinforcing long fibers contained in the resin molding, or by using a dimensional measuring tool such as a straight rule or a vernier caliper.

[0032] The fiber length of the reinforcing long fibers is the average fiber length of 100 or more arbitrarily selected reinforcing long fibers. If there are not 100 or more reinforcing long fibers in the obtained microscope photograph, a new region is photographed with the microscope until the number of reinforcing long fibers reaches 100 or more.

[0033] The reinforcing long fibers may be monofilaments or fibrillated fibers (materials with fibers protruding like whiskers).

[0034] The fibers 6 in the resin molded body 9 preferably include two or more long fibers. The two or more long fibers in the resin molded body are preferably positioned parallel to each other.

[0035] From the viewpoint of further increasing the mechanical strength of the composite 10, the fiber 6 in the resin molded body 9 preferably includes a fiber bundle, and more preferably includes a fiber bundle including a reinforcing long fiber. In the fiber bundle, two or more long fibers are aligned in one direction. The fiber bundle preferably includes two or more long fibers positioned parallel to each other. From the viewpoint of further increasing the mechanical strength and weather resistance of the composite 10, the fiber bundle is preferably included in the resin molded body 9 so that the resin molded body 9 has a surface parallel to the length direction of the fiber bundle. From the viewpoint of further increasing the mechanical strength and weather resistance of the composite 10, the sheet 8 is preferably located on the surface of a surface (side surface) of the resin molded body 9 parallel to the length direction of the fiber bundle. The fiber bundle may be included in the resin molded body 9 so that the resin molded body 9 has at least one surface parallel to the length direction of the fiber bundle. The fiber bundle may be included in the resin molded body 9 so that the resin molded body 9 has at least two surfaces parallel to the length direction of the fiber bundle. The fiber bundle may be included in the resin molding 9 so that the resin molding 9 has at least four surfaces parallel to the length direction of the fiber bundle.

[0036] When the resin molded body 9 is a polygonal column, the length direction of the fiber bundle may be parallel to the end face of the resin molded body 9 or may be parallel to the side face. From the viewpoint of further increasing the mechanical strength and weather resistance of the composite 10, the length direction of the fiber bundle is preferably parallel to the side face of the resin molded body 9. From the viewpoint of further increasing the mechanical strength and weather resistance of the composite 10, when the resin molded body 9 is a polygonal column, the fiber bundle is preferably included in the resin molded body 9 so that the resin molded body 9 has a side face parallel to the length direction of the fiber bundle. From the viewpoint of further increasing the mechanical strength and weather resistance of the composite 10, when the resin molded body 9 is a polygonal column, the fiber bundle is preferably included in the resin molded body 9 so that the resin molded body 9 has a side face parallel to the length direction of the fiber bundle, and the sheet 8 is preferably located on the side face of the resin molded body 9. In this specification, when the resin molded body 9 is a quadrangular column (particularly, a rectangular parallelepiped), the four faces having the longest sides of the quadrangular column are defined as side faces, and the two faces formed by the sides other than the longest side are defined as end faces. In other words, both ends of the rectangular prism in the length direction are end faces, and the faces parallel to the length direction are side faces. In this case, two end faces are located on both sides of the rectangular prism in the length direction.

[0037] When the resin molded body 9 is cylindrical, the length direction of the fiber bundle may be parallel to the end face or the side face of the resin molded body 9. From the viewpoint of further increasing the mechanical strength and weather resistance of the composite 10, when the resin molded body 9 is cylindrical, the length direction of the fiber bundle is preferably parallel to the side face of the resin molded body 9. From the viewpoint of further increasing the mechanical strength and weather resistance of the composite 10, when the resin molded body 9 is cylindrical, the resin molded body 9 is preferably included in the resin molded body 9 so as to have a side face parallel to the length direction of the fiber bundle, and the sheet 8 is preferably located on the side face of the resin molded body 9.

[0038] From the viewpoint of further increasing the mechanical strength of the composite 10, when the resin molded body 9 contains fiber bundles, it is preferable that the cured resin 5X be impregnated between the fibers of the fiber bundles.

[0039] The reinforcing long fiber may be a string-like fiber in which a strand such as a roving or yarn is attached to a binder. In the production of the composite 10, from the viewpoints of easily impregnating the resin composition between the fibers, easily molding the resin molded body 9, and further increasing the mechanical strength of the composite 10, it is preferable that the reinforcing long fiber is a string-like fiber in which a roving is attached to a binder.

[0040] In producing the composite 10, from the viewpoints of easily impregnating the spaces between the fibers with the resin composition, easily molding the resin molding 9, and further increasing the mechanical strength of the composite 10, it is particularly preferable that the reinforcing long fibers be fibers obtained by arranging long glass fiber monofilaments into a roving.

[0041] The lower limit of the fiber diameter of the monofilament is preferably 1 μm or more, more preferably 2 μm or more, and even more preferably 10 μm or more. The upper limit of the fiber diameter of the monofilament is preferably 50 μm or less, more preferably 40 μm or less, and even more preferably 20 μm or less. When the fiber diameter of the monofilament is equal to or more than the above lower limit and equal to or less than the above upper limit, the resin composition can be easily impregnated between the fibers in the production of the composite 10, the resin molded body 9 can be easily molded, and the mechanical strength of the composite 10 can be further increased.

[0042] The fiber diameter is preferably an average diameter. The average diameter is a number average diameter, which is the arithmetic mean value of fiber diameters of 100 randomly selected fibers. The fiber diameter means the diameter of a circle equivalent to a cross section taken along a direction perpendicular to the longitudinal direction of the fiber.

[0043] With respect to the total mass (100 mass%) of the resin molded body 9, the lower limit of the content of the fibers 6 is preferably 20 mass% or more, more preferably 30 mass% or more. With respect to the total mass (100 mass%) of the resin molded body 9, the upper limit of the content of the fibers 6 is preferably 70 mass% or less, more preferably 60 mass% or less, and even more preferably 50 mass% or less. When the content of the fibers 6 is equal to or more than the above lower limit, the mechanical strength and weather resistance of the composite 10 can be further improved. When the content of the fibers 6 is equal to or less than the above upper limit, the resin composition can be easily impregnated between the fibers in the production of the composite 10, the variation in specific gravity of the resin molded body 9 can be reduced, and the abrasion resistance and bending modulus of the composite 10 can be improved.

[0044] The lower limit of the content of the fiber 6 relative to 100 parts by mass of the resin cured product 5X is preferably 40 parts by mass or more, more preferably 50 parts by mass or more. The upper limit of the content of the fiber 6 relative to 100 parts by mass of the resin cured product 5X is preferably 380 parts by mass or less, more preferably 300 parts by mass or less, and even more preferably 200 parts by mass or less. When the content of the fiber 6 is equal to or more than the lower limit, the mechanical strength and weather resistance of the composite 10 can be further improved. When the content of the fiber 6 is equal to or less than the upper limit, the resin composition can be easily impregnated between the fibers in the production of the composite 10, the variation in the specific gravity of the resin molded body 9 can be reduced, and the wear resistance and bending modulus of the composite 10 can be improved.

[0045] The content of the fibers 6 in the resin composition, which is the material of the resin molded body 9, is preferably 40 parts by mass or more, more preferably 50 parts by mass or more, per 100 parts by mass of the resin composition. The content of the fibers 6 in the resin composition is preferably 380 parts by mass or less, more preferably 300 parts by mass or less, and even more preferably 200 parts by mass or less, per 100 parts by mass of the resin composition. When the content of the fibers 6 is equal to or more than the above lower limit, the mechanical strength and weather resistance of the resin molded body 9 can be further improved. When the content of the fibers 6 is equal to or less than the above upper limit, the resin composition can be easily impregnated between the fibers in the production of the composite 10, the variation in the specific gravity of the resin molded body 9 can be reduced, and the wear resistance and bending modulus of the composite 10 can be improved.

[0046] When the resin composition contains a polyol compound and an isocyanate compound, the lower limit of the content of the fiber 6 is preferably 40 parts by mass or more, more preferably 50 parts by mass or more, relative to 100 parts by mass of the total of the polyol compound and the isocyanate compound. When the resin composition contains a polyol compound and an isocyanate compound, the upper limit of the content of the fiber 6 is preferably 380 parts by mass or less, more preferably 300 parts by mass or less, and even more preferably 200 parts by mass or less, relative to 100 parts by mass of the total of the polyol compound and the isocyanate compound. When the content of the fiber 6 is the above lower limit or more, the mechanical strength and weather resistance of the composite 10 can be further improved. When the content of the fiber 6 is the above upper limit or less, in the production of the composite 10, the resin composition can be easily impregnated between the fibers, the variation in the specific gravity of the resin molded body 9 can be reduced, and the abrasion resistance and bending modulus of the composite 10 can be improved.

[0047] <Cured resin> The resin cured product 5X is a cured product of a resin composition. The resin composition contains a resin. Examples of the resin include vinyl resin, thermoplastic resin, curable resin, thermoplastic block copolymer, and elastomer. The resin in the resin composition may be used alone or in combination of two or more kinds.

[0048] Examples of vinyl resins include vinyl acetate resins, acrylic resins, and styrene resins. Examples of thermoplastic resins include polyolefin resins, ethylene-vinyl acetate copolymers, and polyamide resins. Examples of curable resins include epoxy resins, urethane resins, silicone resins, polyimide resins, diallyl phthalate resins, phenolic resins, and unsaturated polyester resins. The curable resins may be room temperature curable resins, thermosetting resins, photocurable resins, or moisture curable resins. The curable resins may be used in combination with a curing agent. Examples of thermoplastic block copolymers include styrene-butadiene-styrene block copolymers, styrene-isoprene-styrene block copolymers, hydrogenated products of styrene-butadiene-styrene block copolymers, and hydrogenated products of styrene-isoprene-styrene block copolymers. Examples of elastomers include styrene-butadiene copolymer rubbers and acrylonitrile-styrene block copolymer rubbers.

[0049] From the viewpoint of improving the processability of the cured resin 5X and the resin molded body 9, the cured resin 5X preferably contains a urethane resin. The urethane resin can be obtained by reacting a polyol compound with an isocyanate compound. Only one type of urethane resin may be used, or two or more types may be used in combination.

[0050] From the viewpoint of improving the processability of the cured resin material 5X and the resin molded body 9, the resin composition preferably contains a polyol compound and an isocyanate compound.

[0051] A polyol compound is a compound having two or more hydroxyl groups (-OH groups). The number of hydroxyl groups in the polyol compound may be 2, 2 or more, 3, 3 or more, 4, or 4 or more. The number of hydroxyl groups in the polyol compound may be 6 or less, 5 or less, or 4 or less. From the viewpoint of improving the processability of the cured product of the resin composition and the resin molded product, the number of hydroxyl groups in the polyol compound is preferably 3 or more and 4 or less.

[0052] Examples of the polyol compound include polylactone polyol, polycarbonate polyol, aromatic polyol, alicyclic polyol, aliphatic polyol, polyester polyol, and polyether polyol. The polyol compound may be a polymer polyol. The polyol compound may be used alone or in combination of two or more kinds.

[0053] From the viewpoint of improving the processability of the cured resin 5X and the resin molded body 9, the polyol compound is preferably a polyester polyol or a polyether polyol.

[0054] The isocyanate compound is a compound having an isocyanate group (-NCO group).

[0055] The number of isocyanate groups in the isocyanate compound may be 1, 2, 2 or more, 3, 3 or more, 4, or more. The number of isocyanate groups in the isocyanate compound may be 6 or less, 5 or less, or 4 or less.

[0056] From the viewpoint of increasing the curing reactivity, the number of isocyanate groups in the isocyanate compound is preferably at least 2. That is, the isocyanate compound is preferably a polyisocyanate compound (an isocyanate compound having at least 2 isocyanate groups).

[0057] Examples of the isocyanate compound include aromatic polyisocyanates, alicyclic polyisocyanates, and aliphatic polyisocyanates. Only one type of isocyanate compound may be used, or two or more types may be used in combination.

[0058] Because of their easy availability and excellent convenience, the isocyanate compound is preferably diphenylmethane diisocyanate (MDI) or modified diphenylmethane diisocyanate, and more preferably diphenylmethane diisocyanate.

[0059] The polyol compound and the isocyanate compound can be used in an appropriate amount so as to efficiently form a urethane bond. The lower limit of the content of the isocyanate compound relative to 100 parts by mass of the polyol compound is preferably 100 parts by mass or more, more preferably 120 parts by mass or more, and even more preferably 130 parts by mass or more. The upper limit of the content of the isocyanate compound relative to 100 parts by mass of the polyol compound is preferably 180 parts by mass or less, more preferably 160 parts by mass or less, and even more preferably 150 parts by mass or less. When the content of the isocyanate compound is within the above range, the reaction efficiency between the polyol compound and the isocyanate compound can be increased, and the amount of unreacted polyol compound or unreacted isocyanate compound can be further reduced. As a result, a composite 10 or a resin molded body 9 having a good flexural modulus can be obtained.

[0060] The cured resin material 5X may be a foamed resin material or a non-foamed resin material. From the viewpoint of reducing the weight of the resin molded body 9, the cured resin material 5X is preferably a foamed resin material.

[0061] When the cured resin material 5X is a foamed resin, the lower limit of the density of the cured resin material 5X is preferably 0.4 g / cm 3 More preferably, 0.6 g / cm 3 The upper limit of the density of the cured resin 5X is preferably 1.2 g / cm 3Less than 1.0 g / cm, more preferably 1.0 g / cm 3 When the density of the cured resin 5X is equal to or higher than the above lower limit, the mechanical strength of the composite 10 can be further increased. When the density of the cured resin 5X is equal to or lower than the above upper limit, the weight of the composite 10 can be reduced. The density of the cured resin 5X can be adjusted by the amount of the foaming agent, the combination of the types of the foaming agents, etc.

[0062] In 100% by mass of the composite, the lower limit of the content of the cured resin 5X is preferably 30% by mass or more, more preferably 40% by mass or more, and even more preferably 50% by mass or more. In 100% by mass of the composite, the upper limit of the content of the cured resin 5X is preferably 80% by mass or less, more preferably 70% by mass or less. When the content of the cured resin 5X is equal to or more than the lower limit, the resin composition can be more uniformly impregnated into the fibers 6 in the production of the resin molded body 9. When the content of the cured resin 5X is equal to or less than the upper limit, the mechanical strength of the composite 10 can be further increased.

[0063] The resin composition may contain other components other than the resin. That is, the resin cured product 5X may contain other components other than the resin. Examples of the other components include a colorant, a foaming agent, a foam stabilizer, a catalyst, a flame retardant, and silica sand. Only one type of other component may be used, or two or more types may be used in combination.

[0064] The resin composition may or may not contain a colorant. The resin composition preferably contains a colorant. That is, the cured resin 5X may or may not contain a colorant, but preferably contains one. Examples of the colorant include pigments and dyes. From the viewpoint of further improving the weather resistance of the composite (particularly, the suppression of color unevenness), the colorant in the resin composition or the cured resin 5X preferably contains a pigment. The colorant in the resin composition or the cured resin 5X preferably contains a black pigment, and more preferably contains carbon black.

[0065] From the viewpoint of further increasing the weather resistance (particularly, suppression of color unevenness) of the composite 10 and improving the quality of the appearance of the composite 10, it is preferable that the cured resin 5X and the sheet 8 (particularly, the coating layer 8B) contain a colorant, and that the colorant in the cured resin 5X and the colorant in the sheet 8 (particularly, the coating layer 8B) have the same color. The colorant in the cured resin 5X and the colorant in the sheet 8 (particularly, the coating layer 8B) may be the same or different.

[0066] A blowing agent is a substance that produces a gas upon decomposition or that is itself a gas.

[0067] The resin composition may or may not contain a foaming agent. From the viewpoint of obtaining a lightweight composite 10 or resin molded body 9, it is preferable that the resin composition contains a foaming agent. When the resin composition contains a foaming agent, the cured resin 5X of the resin molded body 9 becomes a foamed resin. The foamed resin has the advantage of being lightweight.

[0068] Examples of the blowing agent include water and organic halogen compounds. The blowing agent is preferably water because it is easily available and has excellent convenience. Water acts as a blowing agent by reacting with an isocyanate compound to generate CO2. Only one type of blowing agent may be used, or two or more types may be used in combination.

[0069] Examples of the organic halogen compound include an organic chlorine compound, an organic fluorine compound, an organic bromine compound, and an organic iodine compound. The organic halogen compound may be an organic halogen compound in which all hydrogen atoms are replaced with halogen atoms, or an organic halogen compound in which some hydrogen atoms are replaced with halogen atoms. From the viewpoint of improving the foamability during the formation of the resin molded body and maintaining the thermal conductivity of the resin molded body low for a long period of time, the organic halogen compound is preferably an organic chlorine compound or an organic fluorine compound.

[0070] The organic chlorine compound may be a saturated organic chlorine compound, an unsaturated organic chlorine compound, etc. The saturated organic chlorine compound may be dichloroethane, propyl chloride, isopropyl chloride, butyl chloride, isobutyl chloride, pentyl chloride, isopentyl chloride, etc. From the viewpoint of improving the foaming property during the formation of the resin molded body and maintaining the thermal conductivity of the resin molded body low for a longer period of time, the organic chlorine compound is preferably a saturated organic chlorine compound, and more preferably a saturated organic chlorine compound having 2 to 5 carbon atoms.

[0071] The organic fluorine compound includes a saturated organic fluorine compound and an unsaturated organic fluorine compound.

[0072] Examples of the saturated organic fluorine compounds include hydrofluorocarbons. Examples of hydrofluorocarbons include difluoromethane (HFC32), 1,1,1,2,2-pentafluoroethane (HFC125), 1,1,1-trifluoroethane (HFC143a), 1,1,2,2-tetrafluoroethane (HFC134), 1,1,1,2-tetrafluoroethane (HFC134a), 1,1-difluoroethane (HFC152a), 1,1,1,2,3,3,3-heptafluoropropane (HFC227ea), 1,1,1,3,3-pentafluoropropane (HFC245fa), 1,1,1,3,3-pentafluorobutane (HFC365mfc), and 1,1,1,2,2,3,4,5,5,5-decafluoropentane (HFC4310mee).

[0073] Examples of unsaturated organic fluorine compounds include hydrofluoroolefins, such as 2,3,3,3-tetrafluoropropene (HFO-1234yf), 1,3,3,3-tetrafluoropropene (HFO-1234ze) (E and Z isomers), and 1,1,1,4,4,4-hexafluoro-2-butene (HFO1336mzz) (E and Z isomers).

[0074] Further, the organic fluorine compound may be a compound having a chlorine atom, a fluorine atom, and a carbon-carbon double bond. Examples of the compound having a chlorine atom, a fluorine atom, and a carbon-carbon double bond include 1,2-dichloro-1,2-difluoroethene (E and Z isomers) and hydrochlorofluoroolefins. Hydrochlorofluoroolefins include 1-chloro-3,3,3-trifluoropropene (HCFO-1233zd) (E and Z isomers), 1-chloro-2,3,3-trifluoropropene (HCFO-1233yd) (E and Z isomers), 1-(4)chloro-1,3,3-trifluoropropene (HCFO-1233zb) (E and Z isomers), 2-chloro-1,3,3-trifluoropropene (HCFO-1233xe) (E and Z isomers), 2-chloro-2,2,3-trifluoropropene (HCFO-1233xc), 2-chloro-3,3,3-trifluoropropene (HCFO-1233x ...2-chloro-3,3,3-trifluoropropene (HCFO-1233xc) (E and Z isomers), 2-chloro-3,3,3-trifluoropropene (HCFO-1233xd) (E and Z isomers), 2-chloro-3,3,3-trifluoropropene (HCFO-1233xc) (E and Z isomers), 2-chloro-3,3,3-trifluoropropene (HCFO-1233xd) (E and Z isomers), 2-chloro- 3-chloro-1,2,3-trifluoropropene (HCFO-1233xf), 3-chloro-1,2,3-trifluoropropene (HCFO-1233ye) (E and Z isomers), 3-chloro-1,1,2-trifluoropropene (HCFO-1233yc), 3,3-dichloro-3-fluoropropene, 1,2-dichloro-3,3,3-trifluoropropene (HCFO-1223xd) (E and Z isomers), 2-chloro-1,1,1,4,4,4-hexafluoro-2-butene (E and Z isomers), and 2-chloro-1,1,1,3,4,4,4-heptafluoro-2-butene (E and Z isomers).

[0075] From the viewpoint of improving the foaming properties during the formation of the resin molded body 9 and maintaining the thermal conductivity of the resin molded body 9 at a low level for an even longer period of time, the organic halogen compound is preferably a hydrochlorofluoroolefin, a hydrofluorocarbon, or a hydrofluoroolefin.

[0076] Considering the foaming property, the foaming agent can be used at an appropriate content. The lower limit of the foaming agent content (total content when multiple foaming agents are used) is preferably 0.05 parts by mass or more, more preferably 0.1 parts by mass or more, relative to 100 parts by mass of the polyol compound. The upper limit of the foaming agent content is preferably 2.0 parts by mass or less, more preferably 1.5 parts by mass or less, relative to 100 parts by mass of the polyol compound. When the foaming agent content is the lower limit or more, foaming is promoted, the resin molded body 9 is well formed, and the resin molded body 9 is less likely to have dimensional defects. When the foaming agent content is the upper limit or less, it is possible to prevent the resin composition from overflowing from the mold due to excessive foaming.

[0077] The lower limit of the expansion ratio of the urethane resin in the cured resin 5X (i.e., the expansion ratio of the cured resin 5X) is preferably 1.1 times or more, more preferably 1.5 times or more. The upper limit of the expansion ratio of the urethane resin in the cured resin 5X is preferably 5.0 times or less, more preferably 3.0 times or less. When the expansion ratio is the lower limit or more, a lightweight resin molded body 9 or composite 10 is easily obtained. When the expansion ratio is the upper limit or less, a resin molded body 9 or composite 10 having a good flexural modulus is easily obtained.

[0078] The foam stabilizer is a substance that prevents bubbles from becoming coarse and uneven, and enables bubbles to be formed stably and satisfactorily.

[0079] The resin composition may or may not contain a foam stabilizer. Examples of the foam stabilizer include polyoxyalkylene foam stabilizers such as polyoxyalkylene alkyl ethers and silicone foam stabilizers such as organopolysiloxanes. Only one type of foam stabilizer may be used, or two or more types may be used in combination.

[0080] The foam stabilizer can be used in an appropriate content so that the bubbles are stably and satisfactorily formed. From the viewpoint of stably and satisfactorily forming the bubbles, the lower limit of the content of the foam stabilizer is preferably 0.01 parts by mass or more, more preferably 0.1 parts by mass or more, and even more preferably 0.2 parts by mass or more, relative to 100 parts by mass of the polyol compound. The upper limit of the content of the foam stabilizer is preferably 5 parts by mass or less, more preferably 3 parts by mass or less, and even more preferably 1 part by mass or less, relative to 100 parts by mass of the polyol compound.

[0081] <Sheet> The sheet 8 has a base layer 8A and a coating layer 8B disposed on the surface of the base layer 8A. That is, the sheet 8 has a base layer 8A and a coating layer 8B located on one side of the base layer 8A. However, the present invention is not limited to this, and the base layer 8A may have another layer on the other side. Examples of the other layer include a coating layer similar to the coating layer 8B, an adhesive layer, and the like. The sheet 8 is laminated on the surface of the resin molded body 9 from the base material layer 8A side of the sheet 8. That is, the base material layer 8A is located closer to the resin molded body 9 than the coating layer 8B. In the composite 10, the base material layer 8A of the sheet 8 and the resin molded body 9 are in contact with each other. Since the composite 10 according to the present invention has the above-mentioned configuration, it has excellent weather resistance and excellent productivity. More specifically, since the composite 10 according to the present invention has the above-mentioned configuration, it is possible to improve the weather resistance of the composite 10 even when the cured resin 5X of the resin molded body 9 contains a resin with relatively low weather resistance (e.g., a urethane resin).

[0082] Furthermore, since the sheet 8 has the coating layer 8B, the appearance distinctiveness, design, and weather resistance of the composite 10 can be improved.

[0083] The lower limit of the thickness of the sheet 8 is preferably 0.02 mm or more, more preferably 0.05 mm or more, even more preferably 0.1 mm or more, and particularly preferably 0.2 mm or more. The upper limit of the thickness of the sheet 8 is preferably 3.0 mm or less, more preferably 1.5 mm or less. When the thickness of the sheet 8 is equal to or more than the above lower limit, the weather resistance of the composite 10 can be further improved. When the thickness of the sheet 8 is equal to or less than the above upper limit, the flexibility of the sheet 8 can be increased and the sheet 8 can be stored in a rolled form, so that the productivity of the composite 10 can be further improved.

[0084] ≪Base material layer≫ The lower limit of the thickness of the base layer 8A is preferably 0.02 mm or more, more preferably 0.05 mm or more, even more preferably 0.1 mm or more, and particularly preferably 0.2 mm or more. The upper limit of the thickness of the base layer 8A is preferably 3.0 mm or less, more preferably 1.5 mm or less. When the thickness of the base layer 8A is equal to or greater than the lower limit, the weather resistance of the composite 10 can be further improved. When the thickness of the base layer 8A is equal to or less than the upper limit, the flexibility of the sheet 8 can be increased, and the sheet 8 can be stored in a rolled form, so that the productivity of the composite 10 can be further improved.

[0085] From the viewpoint of further improving the weather resistance of the composite 10, it is preferable that the base layer 8A contains fibers. The base layer 8A may be formed only of fibers, or may be formed of fibers and components other than fibers. The base layer 8A may contain fibers and components other than fibers. Examples of components other than fibers include binders. The base layer 8A may or may not contain a binder. The base layer 8A may be formed only of meltable fibers.

[0086] Examples of the fibers in the base layer 8A include glass fibers, asbestos, sepiolite, carbon fibers, rock wool, resin fibers, and pulp. Only one type of fiber may be used in the base layer, or two or more types may be used in combination. Examples of the resin fibers include polyester fibers, polyamide fibers, polyolefin (polyethylene, polypropylene, etc.) fibers, and polyethylene terephthalate fibers.

[0087] The fibers in the base layer 8A preferably contain glass fibers from the viewpoint of further improving the weather resistance of the composite 10. Examples of the base layer 8A containing glass fibers include a glass fiber mat and a glass fiber cloth.

[0088] The fiber-containing base layer 8A may be a nonwoven fabric, a woven fabric, or a knitted fabric. Nonwoven fabrics are generally made by randomly bonding fibers together, and therefore have a porous structure including voids between the fibers. From the viewpoint of increasing the breathability of the sheet and preventing the expansion of the composite due to air accumulating between the resin molded body and the sheet, the fiber-containing base layer 8A is preferably a nonwoven fabric.

[0089] Examples of nonwoven fabrics include spunbond nonwoven fabrics, thermal bond nonwoven fabrics, and spunlace nonwoven fabrics.

[0090] The woven fabric may be a glass fiber cloth or the like. The woven fabric may be a glass fiber cloth. The surface layer of the woven fabric may be treated with plasma or fluorine gas.

[0091] From the viewpoint of further improving the weather resistance of the composite 10, the base layer 8A is preferably a glass fiber mat, a glass fiber cloth, or a nonwoven fabric, and more preferably a glass fiber mat or a glass fiber cloth.

[0092] The lower limit of the fiber diameter of the fibers in the base layer 8A is preferably 3 μm or more, more preferably 5 μm or more. The upper limit of the fiber diameter of the fibers in the base layer 8A is preferably 24 μm or less, more preferably 14 μm or less. When the fiber diameter of the fibers in the base layer 8A is equal to or more than the above lower limit, the weather resistance of the composite 10 can be further improved. When the fiber diameter of the fibers in the base layer 8A is equal to or less than the above upper limit, cracks and chips (surface defects) on the fiber surface can be suppressed, and the weather resistance of the composite 10 can be further improved.

[0093] The fiber diameter is preferably an average diameter. The average diameter is a number average diameter, which is the arithmetic mean value of fiber diameters of 100 randomly selected fibers. The fiber diameter means the diameter of a circle equivalent to a cross section taken along a direction perpendicular to the longitudinal direction of the fiber.

[0094] With respect to the total mass (100 mass%) of the base material layer 8A, the lower limit of the fiber content in the base material layer 8A is preferably 60 mass% or more, and more preferably 80 mass% or more. With respect to the total mass (100 mass%) of the base material layer 8A, the upper limit of the fiber content in the base material layer 8A is preferably 100 mass% or less. When the fiber content in the base material layer 8A is equal to or more than the above lower limit and equal to or less than the above upper limit, the weather resistance of the composite 10 can be further improved.

[0095] Examples of the binder in the base layer 8A include resins. Examples of the resin include polyvinyl alcohol (PVA), acrylic resin, epoxy resin, melamine resin, styrene butadiene rubber (SBR), vinyl acetate resin, vinyl chloride resin, and polyester. Only one type of binder may be used in the base layer, or two or more types may be used in combination.

[0096] The binder in the base layer 8A can be appropriately selected depending on the type of fiber in the base layer 8A. For example, when the fiber in the base layer 8A is glass fiber, the binder in the base layer is preferably polyvinyl alcohol (PVA), acrylic resin, epoxy resin, or vinyl acetate resin.

[0097] The upper limit of the binder content in the base layer 8A relative to the total mass (100% by mass) of the base layer 8A is preferably 40% by mass or less, and more preferably 20% by mass or less. When the binder content in the base layer 8A is equal to or less than the above upper limit, the weather resistance of the composite 10 can be further improved. The lower limit of the binder content in the base layer 8A is not particularly limited. In 100% by mass of the base layer 8A, the binder content in the base layer 8A may be 0% by mass (not contained) or 1% by mass or more.

[0098] The base layer 8A may contain a processing aid. Examples of the processing aid include phthalic acid derivatives, metal carbonates, and metal hydroxides. Only one type of processing aid may be used, or two or more types may be used in combination.

[0099] An example of the phthalic acid derivative is bis(2-ethylhexyl) phthalate.

[0100] The metal carbonate includes calcium carbonate.

[0101] The metal hydroxide may, for example, be aluminum hydroxide.

[0102] The lower limit of the basis weight of the base layer 8A is preferably 20 g / cm 2 More preferably, 40 g / cm 2 The upper limit of the basis weight of the base layer 8A is preferably 200 g / cm 2 Less than 150g / cm 2When the basis weight of the base material layer 8A is equal to or greater than the lower limit, it is possible to further improve the weather resistance of the composite 10. When the basis weight of the base material layer 8A is equal to or less than the upper limit, it is possible to further improve the flexibility of the sheet 8 and store the sheet 8 in a rolled form, thereby further improving the productivity of the composite 10.

[0103] It is expressed as [basis weight of base layer] / [thickness of base layer], and the lower limit of the ratio of the basis weight of the base layer 8A to the thickness of the base layer 8A (basis weight / thickness ratio) is preferably 70 kg / m 3 More preferably, 90 kg / m 3 More preferably, 120 kg / m 3 More preferably, 200 kg / m 3 The upper limit of the weight per unit area / thickness ratio is preferably 1000 kg / m 3 Less than or equal to 900 kg / m 3 Less than 700 kg / m, more preferably 700 kg / m 3 When the basis weight / thickness ratio is equal to or greater than the above lower limit, it is possible to prevent voids in the sheet 8 (particularly the base material layer 8A) from becoming excessively large, and to prevent the resin molding 9 from being exposed on the surface of the composite 10. When the basis weight / thickness ratio is equal to or less than the above upper limit, it is possible to increase the breathability of the sheet 8, and to prevent the expansion of the composite 10 due to air accumulating between the resin molding 9 and the sheet 8.

[0104] When the sheet 8 (particularly, the base layer 8A) has voids, a part of the resin molded body 9 may be exposed from the voids in the sheet 8. The ratio (%) of the area of ​​the exposed part of the resin molded body 9 to the surface area of ​​the part of the resin molded body 9 where the sheet 8 is arranged is defined as the ratio X. The ratio X is preferably 30% or less, more preferably 20% or less, even more preferably 15% or less, even more preferably 10% or less, and particularly preferably 5% or less. When the ratio X is equal to or less than the upper limit, the weather resistance (particularly, the suppression of color unevenness) of the composite 10 can be further improved, and the quality of the appearance of the composite 10 can be improved. The lower limit of the ratio X is not particularly limited. The ratio X may be 0% or more, or may be 1% or more. From the viewpoint of further improving the weather resistance (particularly, the suppression of color unevenness) of the composite 10 and improving the quality of the appearance of the composite 10, the ratio X is most preferably 0%.

[0105] The ratio (ratio X) of the area of ​​the exposed portion of the resin molded body 9 to 100% of the surface area of ​​the portion of the resin molded body 9 where the sheet 8 is disposed can be measured, for example, by the following method. The surface of the composite 10 is photographed using a digital camera or a microscope. The contrast of the photographed image is measured using image analysis software (for example, "WinRoof" manufactured by Mitani Shoji Co., Ltd.). The portion with the highest contrast is regarded as the portion where the resin molded body 9 is exposed, and the ratio of the area of ​​the exposed portion of the resin molded body 9 to 100% of the surface area of ​​the portion of the resin molded body 9 where the sheet 8 is disposed is calculated.

[0106] The ratio of the surface area of ​​the portion where the sheet 8 is arranged to the 100% surface area of ​​the resin molded body 9 is preferably 50% or more, more preferably 60% or more, even more preferably 70% or more, and particularly preferably 80% or more. When the ratio of the surface area of ​​the portion where the sheet is arranged to the 100% surface area of ​​the resin molded body is equal to or more than the above lower limit, the weather resistance (particularly, the suppression of color unevenness) of the composite 10 can be further improved, and the quality of the appearance of the composite 10 can be improved. There is no particular upper limit to the ratio of the surface area of ​​the portion where the sheet 8 is arranged to the 100% surface area of ​​the resin molded body 9. The ratio of the surface area of ​​the portion where the sheet is arranged to the 100% surface area of ​​the resin molded body 9 may be 100% or may be 95% or less.

[0107] <Coating layer> The lower limit of the thickness of the coating layer 8B is preferably 10 μm or more, more preferably 20 μm or more, and even more preferably 50 μm or more. The upper limit of the thickness of the coating layer 8B is preferably 3000 μm or less, more preferably 1500 μm or less. When the thickness of the coating layer 8B is the above lower limit or more, the weather resistance of the composite 10 can be further improved. When the thickness of the coating layer 8B is the above upper limit or less, the flexibility of the sheet 8 can be increased and the sheet 8 can be stored in a rolled form, so that the productivity of the composite 10 can be further improved. In addition, in the sheet 8, a part or all of the coating layer 8B may be impregnated into the base layer 8A. That is, in the sheet 8, a part or all of the coating layer 8B may be integrated with a part or all of the base layer 8A. In particular, when the base layer 8A has voids, it is preferable that a part or all of the coating layer 8B is integrated with a part or all of the base layer 8A. When the entire coating layer 8B is integrated with the entire base material layer 8A, the thickness of the coating layer 8b is the same as the thickness of the base material layer 8A (the thickness of the sheet 8).

[0108] The material of the coating layer 8B preferably contains a curable resin. That is, the coating layer 8B preferably contains a cured product of the curable resin. The curable resin in the material of the coating layer 8B can be appropriately selected in consideration of the function required for the coating layer 8B and the adhesion to the base material layer 8A. Examples of the curable resin in the material of the coating layer 8B include acrylic resin, urethane resin, acrylic urethane resin, silicone resin, acrylic silicone resin, and tetrafluoroethylene resin. Only one type of curable resin may be used in the material of the coating layer 8B, or two or more types may be used in combination.

[0109] From the viewpoint of further improving the weather resistance of the composite body 10, the material of the coating layer 8B preferably contains an acrylic urethane resin, a urethane resin, or an acrylic resin.

[0110] In addition, the coating layer 8B may contain a plasticizer, a dispersant, an anti-settling agent, an emulsifier, a thickener, an antifoaming agent, an anti-algae agent, an anti-mold agent, a preservative, an anti-skinning agent, a drying agent, an anti-sagging agent, a matting agent, a colorant, and a weather resistance imparting agent, etc.

[0111] Examples of the colorant include pigments, dyes, etc. From the viewpoint of further increasing the weather resistance (particularly, suppression of color unevenness) of the composite 10 and improving the quality of the appearance of the composite 10, the colorant in the coating layer 8B preferably contains a pigment, and more preferably contains carbon black.

[0112] The lower limit of the carbon black content in the total mass (100 mass%) of the material of the coating layer 8B is preferably 0.01 mass% or more, more preferably 0.1 mass% or more. The upper limit of the carbon black content in the total mass (100 mass%) of the material of the coating layer 8B is preferably 10 mass% or less, more preferably 3.0 mass% or less. When the carbon black content is equal to or more than the lower limit, the coating layer 8B can be sufficiently colored. When the carbon black content is equal to or less than the upper limit, the fluidity of the material of the coating layer 8B can be increased, and the workability can be improved.

[0113] Examples of the weather resistance imparting agent include an ultraviolet absorbing agent, an antioxidant, and a light stabilizer.

[0114] The lower limit of the coating weight of the coating layer 8B is preferably 80 g / m 2 More preferably, 100 g / m 2 The lower limit of the basis weight of the coating layer 8B is preferably 400 g / m 2 Less than 300 g / m 2 When the basis weight of coating layer 8B is equal to or more than the above lower limit, it is possible to further improve the weather resistance of composite 10. When the basis weight of coating layer 8B is equal to or less than the above upper limit, it is possible to increase the flexibility of sheet 8 and store sheet 8 in a rolled form, so that it is possible to further improve the productivity of composite 10.

[0115] (Other details of the complex) The composites can be used for a variety of purposes, including buildings, vehicles and ships, railway facilities, water treatment facilities, factory facilities, fisheries and aquaculture facilities, electrical equipment, sports and park facilities, and civil engineering sites.

[0116] The composites are suitable for use in buildings for balconies, flooring, foundations, beams, joists, beams, roofs, battens, and the like.

[0117] The composites are suitable for use in vehicles and ships, such as joists, fiber-reinforced plastic (FRP) boats, decks, bulkheads, truck beds, and bridges.

[0118] The composite is suitable for use in railway facilities for sidewalk boards, main three-sail protection boards, platforms, and sleepers (bridge, branch, parallel, short), etc.

[0119] The composite is suitably used in water treatment facilities for covers, drop off panels, stoppers, flocculator blades, doors, louvers, straightening plates, baffle plates, partition plates, inclined plates, and the like.

[0120] The composite material is suitable for use in factory facilities for flooring, walkways, pit covers, chemical tanks, water tanks, workbenches, stands, joists, pallets, freezers, and the like.

[0121] The composite is suitable for use in hatchery tanks, culture tanks, live fish tanks, walkways, etc. in aquaculture facilities.

[0122] The composite is suitable for use in cleats, pipe pillows, and the like in electrical equipment.

[0123] The composites are suitable for use in sports and park facilities, for example for pergolas, bridges, guide boards, gazebos, back screens, tennis practice boards, scoreboards, floating piers, suspension bridges, promenades, ski board core materials, water wheels, and pool components.

[0124] The composite is suitable for use at civil engineering sites as pressure plates, temporary members for direct shield launch (SEW earth retaining walls), and the like.

[0125] The composite is particularly suitable for use as a sleeper. The shape of the sleeper is not particularly limited. The sleeper may be, for example, a rectangular parallelepiped sleeper, or may be a sleeper having a rectangular parallelepiped main body and a protruding portion protruding outward from the main body.

[0126] (Method of Manufacturing the Composite) The method for producing the above-mentioned composite includes a batch production method (first composite production method) and a continuous production method (second composite production method).

[0127] <Batch manufacturing method> The first manufacturing method (batch manufacturing method) of the composite according to the present invention comprises the following steps: a step of placing a sheet in a mold from the coating layer side (sheet placing step), a step of filling the mold with fibers and a resin composition (filling step), and a step of curing the resin composition in the mold (curing step).

[0128] The first production method (batch production method) of the composite according to the present invention has the above-mentioned configuration, and therefore has excellent productivity for the composite, and can improve the weather resistance of the obtained composite.

[0129] In the sheet arrangement step, the sheet 8 is arranged in the mold from the coating layer 8B side. In the sheet arrangement step, the coating layer 8B of the sheet 8 is in contact with the inner surface of the mold. That is, in the sheet arrangement step, the sheet 8 is arranged in the mold so that the coating layer 8B is in contact with the inner surface of the mold. In the sheet arrangement step, the sheet 8 may be arranged on some surfaces in the mold, or may be arranged on all surfaces in the mold. When the mold is cylindrical, the sheet 8 is preferably arranged on the side of the mold. That is, in the sheet arrangement step, the sheet 8 is arranged in a position where the sheet 8 covers the resin molded body 9 (in the composite 10, the four side surfaces of the rectangular prism).

[0130] The method for producing the sheet 8 is not particularly limited. The sheet 8 may be produced by forming the coating layer 8B on the surface of the above-mentioned base layer 8A. When the base layer 8A has voids, the sheet 8 may be produced by permeating the material of the coating layer 8B into the base layer 8A. When the material of the coating layer 8B contains a curable resin, it is preferable that the material of the coating layer 8B is applied onto the surface of the base layer 8A and then cured to form the coating layer 8B.

[0131] In the filling step, the fibers 6 and the resin composition are filled into the mold. In the filling step, when the fibers 6 include long fibers, the long fibers are preferably aligned in any one direction and filled into the mold. In the filling step, when the fibers 6 include short fibers, the short fibers and the resin composition may be mixed and filled into the mold, or the short fibers and the resin composition may be filled into the mold without being mixed.

[0132] In the curing step, the resin composition is cured in a mold. When the resin composition is cured in the mold in which the sheet 8 is placed, the resin molded body 9 including the cured resin 5X is bonded to the sheet 8, and a composite 10 corresponding to the shape of the mold can be produced.

[0133] The curing conditions for the resin composition are not particularly limited and can be appropriately selected depending on the materials in the resin composition.

[0134] When the resin composition contains a foaming agent, the curing step may be a foaming curing step. When the resin composition contains a foaming agent, the curing step preferably includes a step of foaming the resin composition and a step of curing the foamed resin composition.

[0135] Examples of the method for foaming the resin composition include a method of heating the resin composition. The heating time and heating temperature of the resin composition are not particularly limited. The heating time and heating temperature of the resin composition can be appropriately selected according to the type of foaming agent. The heating time of the resin composition in the resin composition may be 5 minutes or more, and may be 60 minutes or less. The heating temperature of the resin composition in the resin composition may be 40°C or more, and may be 80°C or less.

[0136] The method for curing the foamed resin composition is not particularly limited. The curing conditions for the foamed resin composition can be appropriately selected depending on the type of resin in the resin composition.

[0137] If a sheet is not placed in the mold at a position corresponding to the end face of the composite 10, a coating film, which will be described later, may be formed on the end face of the composite 10 after the curing step (coating film forming step).

[0138] <Continuous manufacturing method> The second manufacturing method (continuous manufacturing method) of the composite 10 according to the present invention includes the following steps: A step of advancing the fiber bundle in the length direction of the fiber bundle and supplying the resin composition to the fiber bundle (merging step); A step of impregnating the fiber bundle with the resin composition to obtain a resin-impregnated fiber bundle (impregnation step); A step of arranging a sheet on the surface of the resin-impregnated fiber bundle (sheet arrangement step); A step of curing the resin composition in the resin-impregnated fiber bundle while molding the resin-impregnated fiber bundle and the sheet (curing step). In the second manufacturing method (continuous manufacturing method) of the composite, the fibers in the resin molded body include fiber bundles.

[0139] The second production method (continuous production method) of the composite 10 according to the present invention has the above-mentioned configuration, and therefore has excellent productivity for the composite 10, and can improve the weather resistance of the obtained composite 10.

[0140] FIG. 2 is a diagram for explaining the method for producing a composite (continuous production method) according to the first embodiment of the present invention, and is a schematic diagram of a production apparatus used in the continuous production method.

[0141] 2 includes a first raw material tank 11, a second raw material tank 12, a supply device 15, an impregnation machine 16, a pair of sheet supply rolls 18, and a molding passage (a mold having a heating section) 19. The manufacturing apparatus 100 also includes a first raw material pump 21 that supplies the first raw material 1 stored in the first raw material tank 11 to the supply device 15, and a second raw material pump 22 that supplies the second raw material 2 stored in the second raw material tank 12 to the supply device 15.

[0142] In the manufacturing apparatus 100, the fiber bundle 6A in which the long fibers are aligned in one direction is continuously transported in the length direction of the fiber bundle 6A by a transport means (not shown).

[0143] The impregnation machine 16 includes an impregnation plate 16a and a plurality of kneading plates 16b. The impregnation machine 16 may use an endless belt instead of the impregnation plate. The impregnation machine 16 may include a temperature regulator for adjusting the temperature of the impregnation plate 16a and the endless belt to a predetermined temperature.

[0144] For example, when the cured product of the resin composition is a urethane resin, the polyol liquid as the first raw material 1 may be stored in the first raw material tank 11, and the isocyanate liquid as the second raw material 2 may be stored in the second raw material tank 12. In this case, the polyol liquid is supplied to the supply device 15 by the first raw material pump 21, and the isocyanate liquid is supplied to the supply device 15 by the second raw material pump 22, respectively, and the polyol liquid and the isocyanate liquid are mixed in the supply device 15 to prepare the resin composition 5. The resin composition (the first raw material and the second raw material) may or may not contain a foaming agent. While the fiber bundle 6A is advanced in the length direction, the resin composition 5 is supplied from the supply device 15 to the fiber bundle 6A (merging process). The supply device may be a spraying device. In the merging process, the resin composition may be sprayed onto the fiber bundle by the spraying device.

[0145] The fiber bundle 6A to which the resin composition 5 has been supplied is treated by the impregnation machine 16. In the impregnation machine 16, the fiber bundle 6A is kneaded by the kneading plate 16b on the impregnation plate 16a, and the resin composition 5 is uniformly impregnated between the long fibers constituting the fiber bundle 6A. In this manner, the resin-impregnated fiber bundle 7 is obtained (impregnation process).

[0146] Next, sheets 8 are supplied from a pair of sheet supply rolls 18 to the resin-impregnated fiber bundle 7 so as to sandwich the resin-impregnated fiber bundle 7 from above and below, and the sheet 8 is placed on the surface of the resin-impregnated fiber bundle 7 (sheet placement process).

[0147] The resin-impregnated fiber bundle 7 and the sheet 8 are transferred to a molding passage 19, and the resin-impregnated fiber bundle 7 and the sheet 8 are molded. While the resin-impregnated fiber bundle 7 passes through the molding passage 19, the resin composition 5 in the resin-impregnated fiber bundle 7 hardens to become a resin molded body (not shown) (curing process). In the curing process, the resin molded body and the sheet 8 are bonded to form a composite 10. The resin composition 5 in the resin-impregnated fiber bundle 7 hardens in the molding passage 19, and a composite 10 corresponding to the shape of the molding passage 19 is manufactured. By sequentially transferring the resin-impregnated fiber bundle 7 and the sheet 8 to the molding passage 19, the composite 10 can be manufactured continuously.

[0148] When the resin composition contains a foaming agent, the curing step may be a foaming curing step. When the resin composition contains a foaming agent, the curing step preferably includes a step of foaming the resin composition and a step of curing the foamed resin composition.

[0149] FIG. 3 is a cross-sectional view that typically shows a molding passage in the method for producing a composite body (continuous production method) according to the first embodiment of the present invention.

[0150] The molding passage 19 shown in Fig. 3 is formed by four metal belts 19a. The molding passage 19 is surrounded on four sides by the metal belts 19a. When the molding passage is formed by a plurality of metal belts, the obtained composite 10 can be molded into a variety of shapes.

[0151] The shape of the molding passage is not particularly limited. From the viewpoint of favorably curing and foaming the resin-impregnated fiber bundle (particularly the resin composition) passing through the molding passage, it is preferable that the molding passage has a heating section. From the viewpoint of favorably curing and foaming the resin-impregnated fiber bundle (particularly the resin composition) passing through the molding passage, it is preferable that the molding passage is a mold having a heating section.

[0152] From the viewpoint of favorably curing and foaming the resin-impregnated fiber bundle (particularly the resin composition) passing through the molding passage, the metal belt is preferably heated. From the viewpoint of favorably curing and foaming the resin-impregnated fiber bundle (particularly the resin composition) passing through the molding passage, the heating temperature of the metal belt is preferably 30° C. or higher, more preferably 45° C. or higher, and is preferably 80° C. or lower, more preferably 70° C. or lower.

[0153] The composite (continuous composite) obtained by the batch-type production method or the continuous production method may be cut to a predetermined length as necessary before use. After the composite is cut to a predetermined length, a sheet may be placed on the surface (end face) of the cut surface, or a sheet may not be placed. After the composite is cut to a predetermined length, a coating film may be formed on the surface of the cut surface, or a coating film may not be formed. After the composite is cut to a predetermined length, the resin molded body may be exposed from the cut surface. From the viewpoint of further increasing the weather resistance (particularly, the suppression of color unevenness) of the composite and improving the quality of the appearance of the composite, it is preferable that a sheet is placed on the surface of the cut surface after the composite is cut to a predetermined length, and it is preferable that a coating film is formed on the surface of the cut surface. From the viewpoint of further increasing the productivity of the composite, it is preferable that a sheet is not placed on the surface of the cut surface after the composite is cut to a predetermined length, and it is preferable that a coating film is not formed on the surface of the cut surface.

[0154] In the batch type production method and the continuous type production method, the curing step may be performed after the sheet arrangement step, or the sheet arrangement step may be performed after the curing step. In the batch type production method and the continuous type production method, a sheet may be arranged on the surface of the resin molded body (sheet arrangement step) after the curing step. From the viewpoint of further increasing the productivity of the composite, it is preferable that the curing step is performed after the sheet arrangement step in the batch type production method and the continuous type production method.

[0155] (Other embodiments) In the first embodiment, all surfaces (side surfaces and end surfaces) of the resin molded body are covered with sheets, but the present invention is not limited to this. In the composite, the sheet is disposed on at least a part of the surface of the resin molded body. In the composite, the sheet is disposed on a part or all of the surfaces of the resin molded body. In the composite, the sheet may be disposed on a part of the surface of the resin molded body, or may be disposed on the entire surface of the resin molded body. When the resin molded body is columnar (e.g., polygonal columnar and cylindrical), the sheet may be disposed on the side surface of the resin molded body, or may be disposed on the end surface. From the viewpoint of further improving the weather resistance of the composite, when the resin molded body is columnar (e.g., polygonal columnar and cylindrical), the sheet is preferably disposed on the side surface of the resin molded body. When the resin molded body is columnar (e.g., polygonal columnar and cylindrical), the sheet may be disposed on the end surface of the resin molded body, or may not be disposed. From the viewpoint of further improving the weather resistance of the composite, when the resin molded body is columnar (e.g., polygonal columnar and cylindrical), the sheet is more preferably disposed on the side and bottom surfaces of the resin molded body. The composite may be used with its end surface facing downward, or with its side surface facing downward.

[0156] When the resin molded body is columnar (e.g., polygonal columnar or cylindrical) and no sheet is arranged on the surface of the end face of the resin molded body, a coating film may be arranged on the surface of the end face of the resin molded body. From the viewpoint of enhancing the appearance distinguishability, designability, and weather resistance of the composite, when the resin molded body is columnar (e.g., polygonal columnar or cylindrical) and no sheet is arranged on the surface of the end face of the resin molded body, it is preferable that a coating film is arranged on the surface of the end face of the resin molded body. The coating film may be the same as or different from the coating layer in the sheet. From the viewpoint of enhancing the appearance distinguishability, designability, and weather resistance of the composite, it is preferable that the coating film on the surface of the end face of the resin molded body is the same as the coating layer in the sheet.

[0157] Fig. 4 is a cross-sectional view showing a schematic diagram of a composite body according to a second embodiment of the present invention, in which the same components as those in the first embodiment are denoted by the same reference numerals.

[0158] 4 includes a resin molded body 9 and a sheet 8 disposed on the surface of the resin molded body 9. In the composite 10A, the resin molded body 9 includes fibers 6 and a cured resin 5X. In the composite 10A, the sheet 8 includes a base layer 8A and a coating layer 8B disposed on the surface of the base layer 8A, and the sheet 8 is laminated on the surface of the resin molded body 9 from the base layer 8A side of the sheet 8. That is, the base layer 8A is located closer to the resin molded body 9 than the coating layer 8B.

[0159] The composite 10 shown in FIG. 1 and the composite 10A shown in FIG. 4 have different arrangements of the sheet 8. In the composite 10A, the sheet 8 is arranged on a portion of the surface of the resin molded body 9. In the composite 10A, the sheet 8 is arranged only on one side surface (corresponding to the surface 9a in FIG. 1(a)) of the six sides of the resin molded body 9. In the composite 10A, the sheet 8 is not arranged on the bottom surface (end surface) of the resin molded body 9. In the composite 10A, the sheet 8 is not arranged on three side surfaces (corresponding to the surface congruent and parallel to the surface 9a, the surface 9c, and the surface congruent and parallel to the surface 9c in FIG. 1(a)) of the four side surfaces of the resin molded body 9. That is, the composite body 10A has the sheet 8 only on one side surface, and does not have the sheet 8 on the other three side surfaces and two end surfaces.

[0160] Fig. 5 is a cross-sectional view showing a schematic diagram of a composite body according to a third embodiment of the present invention, in which the same components as those in the first embodiment are denoted by the same reference numerals.

[0161] The composite 10B in FIG. 5 includes a resin molded body 9 and a sheet 8 arranged on the surface of the resin molded body 9. In the composite 10B, the resin molded body 9 includes fibers 6 and a cured product 5X of a resin composition. In the composite 10B, the sheet 8 has a base layer 8A and a coating layer 8B arranged on the surface of the base layer 8A, and the sheet 8 is laminated on the surface of the resin molded body 9 from the base layer 8A side of the sheet 8. That is, the base layer 8A is located closer to the resin molded body 9 than the coating layer 8B.

[0162] The composite 10 shown in FIG. 1 and the composite 10B shown in FIG. 5 have different arrangements of the sheet 8. In the composite 10B, the sheet 8 is arranged on a portion of the surface of the resin molded body 9. In the composite 10B, the sheet 8 is arranged only on two side surfaces (corresponding to the surface 9a and a surface congruent with and parallel to the surface 9a in FIG. 1(a)) among the six surfaces of the resin molded body 9. In the composite 10B, the sheet 8 is not arranged on the surface of the bottom surface (end surface) of the resin molded body 9. In the composite 10B, the sheet 8 is not arranged on two side surfaces (corresponding to the surface 9c and a surface congruent with and parallel to the surface 9c in FIG. 1(a)) among the four side surfaces of the resin molded body 9. That is, the composite body 10A has the sheet 8 only on two side surfaces that are parallel to each other, and does not have the sheet 8 on the other two side surfaces and two end surfaces.

[0163] Fig. 6 is a perspective view showing a schematic diagram of a composite body according to a fourth embodiment of the present invention, in which the same components as those in the first embodiment are denoted by the same reference numerals and the description thereof will be omitted.

[0164] The composite 10C has a rectangular prism-shaped resin molded body 9 and sheets 8 located on the four side surfaces of the resin molded body 9. In this embodiment, the resin molded body 9 does not have sheets 8 on its end faces. In this embodiment, a coating film 130 is located on both end faces of the resin molded body 9 (face 9b and the end face opposite thereto).

[0165] The coating film 130 is a cured product of a coating composition, similar to the coating layer 8B. The coating film 130 may be the same as or different from the coating layer 8B. However, from the viewpoint of improving design and weather resistance, it is preferable that the coating film 130 and the coating layer 8B are the same. EXAMPLES

[0166] The present invention will be specifically described below by way of examples and comparative examples, but the present invention is not limited to the following examples.

[0167] The following materials were prepared:

[0168] (Resin molding) Long glass fiber (long glass fiber made by arranging many monofilaments with fiber diameters of 10 μm to 20 μm into a roving). Polyol compound: polyether polyol with propylene oxide added ("SBU Polyol K660" manufactured by Sumika Covestro Urethane Co., Ltd.). Isocyanate compound: Diphenylmethane diisocyanate (Sumidur 44V20L manufactured by Sumika Covestro Urethane Co., Ltd.). Coloring agent: carbon black (Mitsubishi Chemical Corporation's "MA-100", particle size 24 nm). Foaming agent: water.

[0169] (Sheet with a base layer of glass fiber mat) Sheet 1: Glass fiber mat (Olivest "SB-030", fiber diameter 9μm, fiber length 13mm, binder = PVA + SBR, basis weight = 30g / m 2 , thickness = 0.31 mm) and a coating layer (acrylic resin, basis weight = 56 g / m2) on one surface of the glass fiber mat. 2 ) a sheet having Sheet 2: Glass fiber mat (Olivest "SB-030", fiber diameter 9μm, fiber length 13mm, binder = PVA + SBR, basis weight = 30g / m 2 , thickness = 0.31 mm) and a coating layer (acrylic resin, basis weight = 80 g / m2) on one surface of the glass fiber mat. 2 ) a sheet having a Sheet 3: Glass fiber mat (Olivest "SB-050", fiber diameter 9 μm, fiber length 13 mm, binder = PVA + SBR + crosslinking agent, basis weight = 50 g / m 2 , thickness = 0.37 mm) and a coating layer (acrylic urethane resin, basis weight = 120 g / m2) on one surface of the glass fiber mat. 2 ) a sheet having a Sheet 4: Glass fiber mat (Olivest "SB-073", fiber diameter 9 μm, fiber length 13 mm, binder = PVA + crosslinking agent, basis weight = 73 g / m 2, thickness = 0.54 mm) and a coating layer (acrylic urethane resin, basis weight = 120 g / m2) on one surface of the glass fiber mat. 2 ) a sheet having a Sheet 5: Glass fiber mat (Olivest "SB-073", fiber diameter 9 μm, fiber length 13 mm, binder = PVA + crosslinking agent, basis weight = 73 g / m 2 , thickness = 0.54 mm) and a coating layer (acrylic urethane resin, basis weight = 250 g / m2) on one surface of the glass fiber mat. 2 ) a sheet having a Sheet 6: Glass fiber mat (Olivest "SB-150", fiber diameter 9 μm, fiber length 13 mm, binder = PVA + crosslinking agent, basis weight = 150 g / m 2 , thickness = 1.15 mm) and a coating layer (acrylic urethane resin, basis weight = 120 g / m) on one surface of the glass fiber mat. 2 ) a sheet having a

[0170] (Sheet in which the base layer contains resin fiber or pulp) Sheet 7: Nonwoven fabric (PET fiber, basis weight = 75g / m 2 , thickness = 0.17 mm) and a coating layer (acrylic resin, basis weight = 191 g / m2) on one surface of the nonwoven fabric. 2 ) a sheet having a Sheet 8: Nonwoven fabric (PET fiber, basis weight = 60g / m 2 , thickness = 0.25 mm) and a coating layer (acrylic resin, basis weight = 261 g / m2) on one surface of the nonwoven fabric. 2 ) a sheet having a Sheet 9: Nonwoven fabric (PET fiber, basis weight = 90g / m 2 , thickness = 0.13 mm) and a coating layer (acrylic urethane resin, basis weight = 162 g / m2) on one surface of the nonwoven fabric. 2 ) a sheet having a Sheet 10: Nonwoven fabric (polyester fiber, basis weight = 90g / m 2 , thickness = 0.63 mm) and a coating layer (acrylic urethane resin, basis weight = 343 g / m2) on one surface of the nonwoven fabric. 2 ) a sheet having a Sheet 11: Nonwoven fabric (pulp, basis weight = 51g / m 2 , thickness = 0.055 mm) and a coating layer (acrylic urethane resin, basis weight = 125 g / m2) on one surface of the nonwoven fabric. 2 ) a sheet having a Sheet 12: Nonwoven fabric (PP / PE fiber, basis weight = 70g / m 2 , thickness = 0.22 mm), and a coating layer (acrylic urethane resin composition (1 part by mass of carbon black added to 100 parts by mass of acrylic urethane resin), basis weight = 280 g / m) on one surface of the nonwoven fabric. 2 ) a sheet having a Sheet 13: Nonwoven fabric (PP fiber, basis weight = 45g / m 2 , thickness = 0.57 mm), and a coating layer (acrylic urethane resin composition (1 part by mass of carbon black added to 100 parts by mass of acrylic urethane resin), basis weight = 390 g / m) on one surface of the nonwoven fabric. 2 ) a sheet having a Sheet A: Nonwoven fabric (PP fiber, basis weight = 45g / m 2 , thickness = 0.57 mm) and a coating layer (acrylic urethane resin, basis weight = 390 g / m2) on one surface of the nonwoven fabric. 2 ) a sheet having a Sheet B: Nonwoven fabric with no coating layer on the surface (PP fiber, basis weight = 45g / m 2 , thickness = 0.57 mm). Sheet C: Nonwoven fabric with no coating layer on the surface (PP fiber, basis weight = 90 g / m 2 , thickness = 0.13 mm). Sheet D: Nonwoven fabric (olefin fiber, basis weight = 40g / m 2 , thickness = 0.09 mm) and a coating layer (acrylic urethane resin, basis weight = 100 g / m2) on one surface of the nonwoven fabric. 2 ) a sheet having a Sheet E: Nonwoven fabric (olefin fiber, basis weight = 40g / m 2, thickness = 0.09 mm, plasma surface treatment) and a coating layer (acrylic urethane resin, basis weight = 100 g / m2) on one surface of the nonwoven fabric. 2 ) a sheet having a Sheet F: Nonwoven fabric (olefin fiber, basis weight = 70g / m 2 , thickness = 0.20 mm, fluorine gas surface treatment) and a coating layer (acrylic urethane resin, basis weight = 120 g / m2) on one surface of the nonwoven fabric. 2 ) a sheet having a

[0171] In addition, "Ken Ace" manufactured by Nippon Paint Co., Ltd. was used as the acrylic resin in sheets 1, 2, 7, and 8. In addition, "Mizuyuka" manufactured by Daido Paint Co., Ltd. was used as the acrylic urethane resin in sheets 3 to 6, 9 to 13, A, D, E, and F. In addition, "MA-100" manufactured by Mitsubishi Chemical Corporation (particle diameter 24 nm) was used as the carbon black in sheets 12 and 13.

[0172] (Examples 1 to 17 and Comparative Examples 1 to 3) Using the materials shown in Tables 1 to 4 in the amounts shown in Tables 1 to 4, a composite (square prism shape of 50 mm x 50 mm x 300 mm) was produced as follows, using a production apparatus similar to the production apparatus 100 shown in Fig. 2 (and Fig. 3). As the first raw material shown in Fig. 2, a liquid containing a polyol compound and a foaming agent (1 part by mass of foaming agent per 100 parts by mass of polyol compound) was used. As the second raw material shown in Fig. 2, an isocyanate compound was used.

[0173] <Step of obtaining resin composition> The first raw material placed in the first raw material tank was pumped to a supply device (mixing and spraying device). The second raw material placed in the second raw material tank was pumped to the supply device. The first raw material and the second raw material were uniformly mixed in the supply device to obtain a resin composition.

[0174] <Supply process> The resin composition was sprayed from the discharge port of a supplying device (mixing and spraying device) onto a long glass fiber bundle (a fiber bundle of long glass fibers) in which the long glass fibers were aligned in one direction. The resin composition was sprayed onto the long glass fiber bundle while the long glass fiber bundle was moving in one direction.

[0175] <Merge process> The resin composition and the long glass fiber bundle were kneaded between a kneading plate and an impregnation plate under conditions of 15°C to 25°C, and the resin composition was impregnated between each of the reinforcing long fibers constituting the long glass fiber bundle, thereby obtaining a resin-impregnated fiber bundle in which the resin composition was impregnated into the long glass fiber bundle.

[0176] <Sheet placement process> Sheets were supplied from a pair of sheet supply rolls to the resin-impregnated fiber bundle so as to sandwich the resin-impregnated fiber bundle from above and below, and the sheets were placed on the surface of the resin-impregnated fiber bundle.

[0177] <Curing process (foaming curing process)> The resin-impregnated fiber bundle and the sheet were transferred to a molding passage (a mold with a heating section, heating temperature: 50°C), and the resin composition in the resin-impregnated fiber bundle was cured (foam cured) in the molding passage to obtain a composite.

[0178] In the composites obtained in Examples 1 to 17 and Comparative Examples 1 to 3, the length direction of the long fibers was parallel to the side surfaces of the resin molding (i.e., the long fibers extended from one end surface of the resin molding to the other end surface), and the sheets were placed on the surfaces of the four side surfaces of the resin molding. Note that the sheets were not placed on the surfaces of the end surfaces of the resin molding.

[0179] (Evaluation method) <Percentage X> The obtained composite was measured for the ratio X (the ratio of the area of ​​the exposed part of the resin molded body to the surface area of ​​the part of the resin molded body where the sheet is arranged, which is 100%) by the above-mentioned method. Note that in Examples 12 and 13, the resin molded body and the sheet contained the same colorant, so the ratio X could not be measured.

[0180] <Weather resistance> The composite was irradiated with light under the following conditions using a Sunshine Weather Meter ("WEL-SAN-HC" manufactured by Suga Test Instruments Co., Ltd.). The surface of the composite after light irradiation was observed to see whether the glass fibers in the resin molding were exposed from the surface of the composite. The surface of the composite after light irradiation was also observed to see whether color unevenness occurred. The weather resistance of the composite was judged according to the following criteria. ·Irradiation intensity: 255W / m 2 . ·Wavelength: 300nm~700nm. - Irradiation time: 1000 hours.

[0181] <Weatherability (exposed glass fibers) criteria> ○: No exposed glass fibers. ×: Glass fibers are exposed.

[0182] <Weatherability (color unevenness) evaluation criteria> XX: No color unevenness occurs. ○: Color unevenness is very slight (no problem in practical use). ×: Color unevenness occurs.

[0183] The compositions and results are shown in Tables 1 to 4 below.

[0184] [Table 1]

[0185] [Table 2]

[0186] [Table 3]

[0187] [Table 4]

[0188] In addition, in Examples 1 to 17, the composite could be efficiently manufactured by disposing the sheet on the surface of the resin molded body, and the productivity was good. In addition, in the composites of Examples 12 and 13, the resin molded body and the sheet (particularly the coating layer) contained the same coloring agent, so the occurrence of color unevenness on the surface of the composite was particularly effectively suppressed, and the quality of the appearance of the composite was maintained at a high level. [Explanation of symbols]

[0189] 1...First raw material 2...Second raw material 5...Resin composition 5X...cured resin 6…Fiber 6A…Fiber bundle 7…Resin-impregnated fiber bundle 8…Sheet 8A…Base material layer 8B…Coating layer 9...Resin molding 9a, 9b, 9c…planes 10,10A,10B,10C…complex 11…First raw material tank 12…Second raw material tank 15…Feeding device 16...Impregnation machine 100...Manufacturing equipment

Claims

1. A resin molded body and a sheet covering a part or all of a surface of the resin molded body, The resin molded body has a cured resin and one or more fibers, The sheet has a base layer and a coating layer located on one surface of the base layer, The composite body, wherein the base material layer is located closer to the resin molded body than the coating layer.

2. The resin molded body includes two or more fibers, The two or more fibers are parallel to each other, The composite according to claim 1 , wherein the sheet is located on a part or all of a surface of the resin molded body that is parallel to a longitudinal direction of the fibers.

3. The resin molded body has a polygonal columnar shape, the fibers included in the resin molding extend from one end surface of the resin molding to the other end surface of the resin molding, The composite body according to claim 2 , wherein the sheet is positioned on a part or all of a side surface of the resin molded body.

4. The composite of claim 1 or 2, wherein the substrate layer comprises fibers.

5. The composite according to claim 1 or 2, wherein the substrate layer is a glass fiber mat, a glass fiber cloth or a nonwoven fabric.

6. placing the sheet in a mold; filling the mold with the fibers and a resin composition; curing the resin composition in the mold to form a composite; The method for producing the complex according to claim 1 or 2, comprising the steps of:

7. A step of supplying a resin composition to the fiber bundle while advancing the fiber bundle in the length direction of the fiber bundle, in which the two or more fibers are aligned in one direction; impregnating the fiber bundle with the supplied resin composition to obtain a resin-impregnated fiber bundle; placing the sheet on a surface of the resin-impregnated fiber bundle; passing the resin-impregnated fiber bundle together with the sheet through a molding passage to cure the resin composition into a continuous composite; cutting the continuous composite to a desired length; The method for producing the composite according to claim 2, comprising:

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