JP2000185384A - Panel material for water section structure and production thereof - Google Patents

Abstract

PROBLEM TO BE SOLVED: To develop and produce a panel for a water section structure excellent in water resistance, lightweight properties and abrasion resistance, capable of freely cutting out a member with a predetermined size and excellent in cutting processability. SOLUTION: A panel material consists of a molding resin surface material layer having an anti-slip surface pattern and bending strength of 5-30 kgf/mm3, a closed cell type high density hard polyurethane foam layer with a molding density of 0.1-0.5 g/cm3 and a molding resin surface material layer with bending strength of 5-30 kgf/cm3. This panel material can be used in a water using structure such as a floating pier, a floating island, a water promenade, a water stage, a water house or a floor or wall of a ship.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

TECHNICAL FIELD The present invention relates to water resistance, light weight,
The present invention relates to a panel material which is excellent in rigidity, impact resistance, cutting workability, screw accommodating property, easily cut out to a predetermined size, and a method of manufacturing the same. More specifically, it relates to a floating pier, a water promenade, a floating island, a ship The present invention relates to a panel for surrounding water structures such as floors and walls and a method for producing the same.

[0002]

2. Description of the Related Art Conventionally, wood has been widely used for water-related structures such as floating piers and promenades, as is well known. However, preservatives are used because they cause rotting problems when used for a long period of time, but they still do not have sufficient durability. Further, since high-density and heavy wood is used in order to enhance durability, the center of gravity of the structure is increased and stability is deteriorated, and a large number of floating bodies are required, and the structure tends to be large. In addition, there are problems such as the fact that the preservatives used cause environmental pollution, and from the viewpoint of environmental protection, the regulation of felling of southern timber is becoming stronger, making it difficult to obtain high quality wood.

For this reason, it has been proposed to use a resin foam generally called synthetic wood as a construction around water. These generally increase the rigidity by reinforcing the interior of the resin foam with glass fibers or the like, but the rigidity is not necessarily high, so that the thickness needs to be increased more than necessary. For this reason, although the specific gravity of the resin foam itself is low, the effect of improving the weight, which is heavy in terms of the weight per unit area, is low. Further, the resin foam has a low surface hardness, which is disadvantageous in terms of durability, and there is also a problem of screw accommodation such that screws at the time of attachment to the frame are hardly effective. Further, the urethane resin undergoes discoloration by light, so when the appearance is regarded as important, secondary processing such as painting is required, which increases the cost. Furthermore, even for slippage that requires the most attention around water, it is necessary to attach a non-slip material to the surface or to perform secondary processing such as sanding, which results in extremely high costs.

[0004]

SUMMARY OF THE INVENTION The present invention eliminates these problems and can cut out a member of a predetermined size with excellent water resistance, light weight, abrasion resistance and impact resistance. The purpose of the present invention is to develop a panel for a plumbing construction, which is excellent in cutting workability and screw settability that can be screwed.

[0005]

Means for Solving the Problems The inventors of the present invention have conducted various studies in view of the above problems, and as a result, have completed the present invention with a specific foamed material containing no fiber reinforcing material and a molded resin surface material. It has been reached.

That is, the present invention provides (A) a molded resin surface material layer having a non-slip surface pattern and a bending strength of 5 to 30 kgf / mm ³ , and (B) a molded density of 0.1 to 0.5 g / cm ^3. Consisting of a closed-cell high-density rigid polyurethane foam layer, (C) a molded resin surface material layer having a bending strength of 5 to 30 kgf / mm ³ , a floating pier, a floating island, a water promenade, a water stage,
Water-based houses, panel materials for water-around structures characterized by being used for water-around structures such as floors and walls of ships, preferably having a specific gravity of 0.2 to 0.8, and easily drilled on site. , That processing such as cutting is possible, preferably that the molding resin surface material (A) uses at least one layer of a fiber reinforcing material and uses a thermosetting resin as a matrix resin, and preferably has a high density. Rigid polyurethane foam (B)
Has a flexural modulus of 5 to 300 kgf / mm ² and a thickness reduction of 10% or more after 50% compressive deformation and pressure release, preferably thermosetting of the molded resin surface materials (A) and (C) in rESIN radically polymerizable unsaturated resin, the fiber reinforcement of one per unit weight 100 to 800 g / m ² alone or a plurality of use, the total basis weight of 100 to 2000 g / m ^2, preferably molded resin The thickness of the surface materials (A) and (C) is 0.6 to
3.0 mm / sheet, rigid urethane foam (B) has a thickness of 5 to 30 mm, and raw polyurethane foam material is injected into a gap between two molded resin surface material layers set in a mold. The present invention provides a method for producing a panel material for a water surrounding structure, comprising a step of foaming and integrally molding, and a step of cutting out the obtained sandwich panel into a predetermined size.

[0007]

BEST MODE FOR CARRYING OUT THE INVENTION The molded resin surface material layers (A) and (C) used in the present invention are molded resin surface materials having a non-slip surface pattern and a bending strength of 5 to 30 kgf / mm ³ ,
It is preferably a plate having a thickness of 0.6 to 3.0 mm / sheet, and preferably a fiber reinforced material impregnated with a thermosetting molding resin. As the thermosetting resin, for example, unsaturated polyester resin, phenol resin, epoxy resin,
Examples of the vinyl ester resin include a radically polymerizable unsaturated resin (an unsaturated resin dissolved in an unsaturated polymerizable monomer such as styrene), such as an unsaturated polyester resin or a vinyl ester resin. (Epoxy acrylate resin, urethane acrylate resin, unsaturated polyester acrylate resin). The Shore D hardness of the cured thermosetting resin is preferably 85 or more. This molded resin surface material has excellent properties in terms of mechanical properties such as surface hardness and flexural modulus, ease of work such as cutting in the field, etc. And more preferably a molded plate using an unsaturated polyester resin. Commercially available thermosetting molding resins include unsaturated polyester resin "Polylite" (LP-921 etc., Dainippon Ink & Chemicals, Ltd.) and vinyl ester resin "Dicklight" (UE-3505 etc., Dainippon Ink Chemical Industrial Products) can be used.

As the fiber reinforcing material used for the molded resin surface material layers (A) and (C), glass fiber is preferably used. Of course, in order to further reduce the weight, organic high elastic fibers such as carbon fiber and aramid are used. , A nonwoven fabric, or the like, or a glass fiber can be used in combination.

The shape of the fiber reinforcing material used for the molding resin surface material is, for example, chopped strand mat, roving,
Roving cloths, cloths and the like can be mentioned, and any of these can be used.

[0010] As the fibrous reinforcement, preferably with the total basis weight is 100 to 2000 g / m ² to be used, either alone or a plurality of fiber reinforcement to the weight per unit area per sheet and 100 to 800 g / m ² use. At that time, mat-like and / or cloth-like materials may be used alone or in combination. The mat shape preferably has a basis weight of 100 sheets.
A chopped strand mat having a basis weight of 100 to 80 g / m ^2.
It is a roving cloth of 0 g / m ² .

The proportion of the fiber reinforcing material used in the molded resin surface material layers (A) and (C) is preferably from 20 to 70% by weight, more preferably from 30 to 50%. This also applies to the case where organic high-elastic fibers such as carbon fibers and aramid fibers, and nonwoven fabrics are used or used in combination. If the ratio of the fiber reinforcement is less than 20%, a sufficient bending elastic modulus cannot be obtained,
If it exceeds 70%, the impact resistance is undesirably reduced.

The thickness of the molded resin surface material layers (A) and (C) is 0.6
~ 3.0 mm is preferred. If the thickness is smaller than this, there is a problem in terms of impact resistance, bending properties, and the like. If the thickness is larger than this, it becomes difficult to use it in terms of workability, weight, cost, and the like as a structure around water.

The method for producing the molded resin surface material is not particularly limited, and those produced by a known method can be used without any problem. As an example of the outline of this production method, first, a fiber reinforced material such as a glass mat is impregnated with a thermosetting molding resin such as an unsaturated polyester resin, and then cured in a drying oven at 60 ° C. for 1 hour. The plate is removed from the mold and cut to a predetermined size to obtain a plate.

It is desirable that the molded resin surface material layers (A) and (C) and the rigid polyurethane foam layer (B) are directly adhered to each other. The surface in contact with the rigid polyurethane foam layer (B) is sanded or primed before use. This is to improve the adhesiveness between the rigid urethane foam layer (B) and the molded resin surface material layers (A) and (C) in the step of injecting and foaming the rigid polyurethane foam material.

The rigid polyurethane foam layer (B) of the present invention
Since the panel material for surrounding water structures for the purpose of the present invention is required to have high workability, mechanical strength, especially bending strength, and high flexural modulus, use a closed cell type among rigid polyurethane foams. I have.

The rigid polyurethane foam has a high density,
Preferably, the reduction in thickness after 50% compression deformation release is 10%.
As described above, the flexural modulus is 5 to 200 kgf / mm.
It is preferably ² .

The rigid polyurethane foam raw material used in the present invention refers to a raw material for producing a rigid polyurethane foam or a rigid urethane-modified polyisocyanurate foam. These are preferably obtained from a polyol compound and a polyisocyanate.

Here, the polyol compound used in the present invention mainly includes polyol,
A material composed of a catalyst, a foam stabilizer, a foaming agent, a flame retardant, and the like.

Among them, the above-mentioned polyols include, for example, those having a structure in which an alkylene oxide is added to a compound having at least two active hydrogen atoms, or a mixture thereof, which is a polyether. Polyols; polyhydric alcohols,
Polyester polyols composed of polyhydric carboxylic acids or lactones; and polyetherester polyols having both bonds are also included.

If only typical representative examples of polyether polyols are given as examples, polyhydric alcohols, polyhydric phenols or amines are used as initiators, respectively. It is a form obtained by adding various alkylene oxides such as ethylene oxide, propylene oxide or butylene oxide.

If only typical initiators used in these polyether polyols are exemplified, first, polyhydric alcohols include:
Including various dihydric alcohols such as ethylene glycol, propylene glycol, butanediol, hexanediol, diethylene glycol, neopentyl glycol or 3-methyl-1,5-pentanediol, glycerin, trimethylolpropane,
Various trihydric alcohols such as hexanetriol or trimethylolethane; or various tetrahydric or higher alcohols such as pentaerythritol, sorbitol, methylglucoside or sucrose, and polyhydric phenols such as pyrogallol Or various compounds such as hydroquinone, or other various compounds such as various bisphenols such as bisphenol A.

Further, only typical representative examples of polyvalent polycarboxylic acids are given below, and various aliphatic polycarboxylic acids such as succinic acid, oxalic acid or adipic acid; phthalic acid, trimellitate Various aromatic polycarboxylic acids, such as acids or hetacids.

Further, if only typical amines are exemplified, various monoamines such as ammonia, alkylamine or aniline; ethylenediamine, diethylenetriamine, tolylenediamine, piperazine, diaminodiphenylmethane or aminoethyl Various polyamines such as piperazine; various alkanolamines such as monoethanolamine, diethanolamine, triethanolamine, monopropanolamine, dipropanolamine or tripropanolamine.

If only typical polyester polyols are exemplified, the glycol components may be ethylene glycol, propylene glycol, butanediol, hexanediol, diethylene glycol, dipropylene glycol, neopentyl glycol or 3-methyl-glycol. Various dihydric alcohols such as 1,5-pentanediol; glycerin, trimethylolpropane or trimethylolethane,
Various trihydric alcohols; various polyhydric alcohols having a valency of 4 or more such as pentaerythritol, and various aliphatic polycarboxylic acids such as succinic acid, oxalic acid or adipic acid as a carboxylic acid component. Acids;
Examples thereof include those obtained by using various aromatic polycarboxylic acids such as phthalic acid, trimellitic acid, and heptic acid.

For preparing the polyetherester polyol, for example, polyols having both an ether bond and an ester bond in the molecule, which are obtained by using the above-mentioned various raw materials, can be used.

Of these, preferred are polyether polyols obtained by using an aliphatic compound as an initiator, and more preferred are those obtained by using a polyhydric alcohol or an amine as an initiator. And particularly preferable ones are 5
Various polyether polyols as described above having a hydroxyl value of 00 (mg KOH / g) or less.

20% by weight of this polyether polyol
The polyol compound in the form used above has excellent compatibility with the fluorine-containing halogenated hydrocarbon-based blowing agent, and is particularly preferable.

As the foaming agent, water, which is a reactive foaming agent, and fluorine-containing halogenated hydrocarbon or fluorine-containing hydrocarbon having at least one hydrogen atom in the molecule, if necessary, may be used. Although only typical representative examples of such fluorinated (halogenated) hydrocarbons are exemplified, trifluoromethane, difluoromethane, pentafluoroethane, difluoroethane, dichloromonofluoromethane, monochloromonofluoromethane, monochlorofluoromethane, Dichlorotrifluoroethane, dichlorofluoroethane, monochlorotetrafluoroethane, monochlorodifluoromethane or monochlorodifluoroethane can be used. Furthermore, it is also possible to use a low boiling halogenated hydrocarbon such as methylene chloride in combination.

As the above-mentioned polyisocyanate used in the present invention, if only typical ones are exemplified, there may be mentioned, for example, hexamethylene diisocyanate.
Various aliphatic polyisocyanates; various alicyclic isocyanates such as hydrogenated diphenylmethane diisocyanate or isophorone diisocyanate; various aromatic isocyanates such as tolylene diisocyanate (TDI) and diphenylmethane diisocyanate (MDI); In addition, Crude TDI, Crude MD
I, isocyanurate-modified prepolymers or isocyanurate-modified prepolymers.

Examples of the above-mentioned catalysts used in the present invention include various amine-based catalysts such as hexamethylenediamine, pentamethyldiethyltriamine or imidazole; octyl. Catalysts for preparing various urethane-modified polyisocyanurate foams, such as potassium citrate or triazine; or dibutyltin dilaurate (D
And various metal catalysts such as BTL).

The rigid polyurethane foam layer (B) used in the present invention has a molding density of 0.1 to 0.5 g / cm ³ . When the molding density is lower than this, since the foam strength is low, not only the bending strength, the bending elastic modulus and the like of the panel material for water surrounding structures are particularly lowered as the panel material of the present invention, but also the foam layer is not concentrated on concentrated load. (B) tends to buckle. Conversely, the molding density of the foam layer (B) is set to 0.5 g / cm ³
If it is larger, the panel material of the present invention not only becomes heavy, but also is not preferable from the viewpoint of workability and cost on site. More preferably 0.25 to 0.35 g / cm
³

In addition, it is preferable that the material is closed cell mainly from the viewpoint of mechanical strength. The closed cell rate is preferably at least 80%, particularly preferably at least 90%. The cell size of the rigid polyurethane foam is not particularly limited, but the cell diameter is preferably 1 to 1000 microns from the viewpoint of strength and moldability.

The thickness of the high-density rigid polyurethane foam as the core material of the present invention is determined in consideration of the thickness of the molded resin surface material layers (A) and (C) and the thickness of the finally obtained panel material. , Preferably 5 to 30 mm.

The thickness of the panel material of the present invention is preferably 1
0 to 36 mm. It is not preferable that the thickness of the panel material be thicker than this because not only the weight becomes heavy but also the cost becomes high. Further, if the thickness of the panel material becomes thinner than this, there is a problem in terms of strength and bending of the member. The specific gravity of the panel material is preferably 0.2 to 0.8. If the specific gravity is larger than this, the feeling of lightweight is lacking. More preferably, it is 0.3 to 0.6.

As a method of producing the panel material for a water surrounding construction according to the present invention, preferably, the molded resin surface material layers (A) and (C) are formed in a box mold controlled at 30 to 70 ° C. The molding resin surface material is set to the thickness of the panel material required by the spacer, and the rigid polyurethane foam raw material is injected into the gap and foamed at a predetermined magnification, preferably 2 to 4 times,
After the foaming and curing of the polyurethane foam raw material, the molded resin surface material layer (A) / hard polyurethane foam layer (B) / molded resin surface material layer (C), which is used as a panel material for a plumbing building from the box-shaped mold, Then, a panel having a sandwich structure is taken out, the end is cut out and cut into a predetermined “length × width” quadrilateral size, and the four ends are painted in a similar color to form a panel material for a water-around construction.

Next, if necessary, the panel material is cut into a predetermined size. For example, if it is used as a floor material of a floating pier, its width (length) is preferably 9
00-1200mm, length (horizontal) 1800-3000mm
It is.

The weight ratio between the molded resin surface material layers (A) and (C) and the rigid polyurethane foam layer (B) of the panel material thus obtained is preferably (A) + (C) / (B) = 15. ~ 75/85
~ 25 (% by weight), more preferably 25 ~ 65/35 ~
75 (% by weight).

Further, the cut end surface (cut surface, cut foam surface) of the cut panel material is colored in the same color as the molding resin surface material layer as the surface material, if necessary, mainly from the viewpoint of aesthetics and durability. A molded resin, for example, an unsaturated polyester resin, an acrylic resin, a urethane resin, a melamine resin, or the like is also applied. Further, protective materials may be provided at four sides and four corners.

The shape of the panel material of the present invention may be a curved surface, a flat surface,
An uneven surface may be used. Preferably it is a flat plate. The surface of the panel material has a non-slip surface pattern,
Those sanded and those having a small uneven surface are preferred. In addition, those with no pattern and small irregularities are more preferable because they have high anti-slip effect.

The non-slip irregularities of the surface material are not particularly limited in shape, but are preferably those having concave portions of a grain pattern, a linear pattern, a curved pattern, and a lattice pattern. The width is about 0.1 to 20 mm. Further, a pattern such as a large circle or a square may include the small uneven pattern.

The water surrounding structure of the panel for a water surrounding structure is a floating pier, a floating island, a water promenade, a water stage, a water house, a ship, a raft, etc., a building used on or around the water or a floor material for amusement facilities. , Wall materials, signboards and the like. Preferably, a floor material such as a floating pier or a water promenade is used.

The panel material obtained by the present invention can be used in the same manner as ordinary wood, for example, cutting with a saw, nailing, screwing, drilling, etc. It is possible to use tools and the like as they are.

[0043]

EXAMPLES The present invention will be described below with reference to examples. Unless otherwise specified, "parts", "%", and the like are on a weight basis.

(Example 1) As a fiber reinforcing material, 300 g /
Two sheets of m ² chopped strand mats were piled up and impregnated with an unsaturated polyester resin (Polylite LP-921, Dainippon Ink & Chemicals, Inc.) to obtain a surface material A used for a molded resin surface material layer. The thickness of the molded resin surface material A is 1.
At 0 mm, the percentage of fiber reinforcement was about 40% by weight.

Next, 1 m × 2.5 m × 1 which was adjusted to 45 ° C.
Two molding resin surface materials A were set in a 5 mm box-shaped molding die, and a rigid polyurethane foam material was injected and foamed between them, and the thickness of the rigid polyurethane foam layer was 13 m.
m, and a sandwich panel material (having a thickness of 15 mm and a specific gravity of about 0.5) having a molding density of 0.3 g / cm ³ was obtained.

At this time, the rigid polyurethane foam material had a hydroxyl value of 4 using pentaerythritol as an initiator.
50 polyhydric alcohol-based polyether polyol 100
Part, water as a foaming agent 0.5 part and monofluoroethane 1
0 parts, and 0.5 part of hexamethylenediamine as a catalyst.
It is composed of a combination of 4'-diphenylmethane diisocyanate (MDI).

Next, this sandwich panel material was
It was cut out into a size of mm × 2400 mm and evaluated as a panel for surrounding water structures. The results are shown in Table 1.

Example 2 As a fiber reinforcing material, a knitted 230 g / m ² roving cloth, a 300 g / m ² chopped strand mat, and a knitted 230 g / m ²
overlapping m ² roving cloth in this order to give it the unsaturated polyester resin (Polylite LP-921, Dainippon Ink and Chemicals Products) The surface material B used in the molding resin surface material layer B impregnated. The thickness of the molded resin surface material B is 1.5 mm
The proportion of the fiber reinforcement was about 40% by weight.

Next, 1 mx 2.5 mx 1 adjusted to 45 ° C.
Two molding resin surface materials B were set in a 5 mm box-shaped molding die, and a rigid polyurethane foam material was injected and foamed between them to form a rigid polyurethane foam layer having a thickness of 12 mm.
A sandwich panel material (having a thickness of 15 mm and a specific gravity of about 0.5) having a molding density of 0.3 g / cm ³ was obtained.

At this time, the same rigid polyurethane foam material as in Example 1 was used. The results are shown in Table 1.

Comparative Example 1 A commercially available 15 mm thick Ipe wood (wood from South America) was evaluated in the same manner as in Comparative Example 1. The specific gravity of the ipe was about 1.2. The results are shown in Table 1.

[0052]

[Table 1]

Note) Surface hardness: Measured by Shore D hardness meter Water absorption: JIS Z 2101 compliant

From the above, it was found that the panel material of the present invention is lightweight, has high water resistance and high abrasion resistance, has excellent cutting workability, and is easily cut into a predetermined size.

[0055]

According to the present invention, by using a specific molding resin surface material as the surface material layers (A) and (C), the surface durability and abrasion resistance are excellent, and the gap between the two molding resin surface materials is further improved. By injecting and foaming the rigid polyurethane foam raw material to form a rigid urethane foam layer (B) having a specific molding density, the interface between the molded resin surface material layer (A) (C) and the rigid polyurethane foam layer (B) An object of the present invention is to provide a panel material for a construction around water, which has a strong adhesive force, is excellent in light weight and abrasion resistance, and is excellent in cutting workability that a member of a predetermined size can be cut out freely and water resistance. Therefore, the panel material of the present invention can be used as a floating pier, floating island, floating promenade, floating stage, floating house, floor or wall of a building or amusement facility used on or around water such as a floor or wall of a ship. Useful.

 ──────────────────────────────────────────────────続 き Continuing on the front page F term (reference) 4F100 AK01A AK01C AK51B BA03 BA07 BA10A BA10C BA15 DD01A DH02A DJ01B EC152 EH132 EH312 EJ022 GB07 GB90 JA13 JA14B JA20A JA20B JA20C JB07 JB13A JK04 JKJBJJJB00 YY00B YY00C

Claims (7)

[Claims] 1. A molded resin surface material layer having a non-slip surface pattern and a bending strength of 5 to 30 kgf / mm ³ ,
A closed-cell high-density rigid polyurethane foam layer having a molding density of 0.1 to 0.5 g / cm ³ , (C) a bending strength of 5 to 30
A panel for surrounding water structures comprising a molded resin surface material layer of kgf / mm ³ and used for surrounding structures such as floating piers, floating islands, floating promenades, floating stages, floating houses, ship floors and walls. Wood. 2. The panel material has a specific gravity of 0.2 to 0.8,
2. The panel material according to claim 1, wherein drilling, cutting and the like can be easily performed on site. 3. The molding resin surface material (A) according to claim 1, wherein at least one layer of a fiber reinforced material is used, and a thermosetting resin is used as a matrix resin. Panel materials. 4. High density rigid polyurethane foam (B)
But bending modulus 5~300kgf / mm ^2, panels of claims 1 to 3, wherein any one, wherein the reduction of 50% compressive deformation depressurization of thickness is more than 10%. 5. The thermosetting resin of the molding resin surface materials (A) and (C) is a radical polymerizable unsaturated resin, and the fiber reinforcing material has a basis weight of 100 to 800 g / m ² singly or in combination. ,
The total basis weight of 100 to 2000 g / m ² and the panel member according to any one of claims 1 to 4, characterized in that. 6. The molding resin surface material (A) (C) has a thickness of 0.6
The thickness of the rigid urethane foam (B) is 5 to 30 mm at a thickness of 1 to 3.0 mm / sheet.
5. The panel material according to any one of 5. 7. A step of injecting and foaming a rigid polyurethane foam raw material into a gap between two molding resin surface material layers set in a mold and integrally molding the same, and a step of cutting out a predetermined size from the obtained sandwich panel. A method for manufacturing a panel material, comprising: