JP2003064858A - Structural body and its molding method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a crack-free construction structural body formed by laminating a base forming a floor or a roof with a resin and to effectively use resources by reusing waste FRP molding and waste rubber as a crushed material and a rubber chip for a fiber reinforced resin molding. SOLUTION: On the base, a resin layer 1 principally consisting of a crushed material A of the fiber reinforced resin molding or consisting of the crushed material A of the fiber reinforced resin molding, a rubber chip B, and a liquid thermosetting resin C serving as a binder is formed, and then, a polymer material layer 2 is formed on the resin layer.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a thermosetting resin fiber reinforced molded article and a rubber chip, and in particular, a structure obtained by laying on a base a mixture or recovered material thereof and a mixture of the thermosetting resin as a binder, and It relates to the construction method.

[0002]

2. Description of the Related Art A resin material is laminated on a base of a building structure, that is, a base forming a floor or a roof to reinforce or waterproof it. For example, when a floor is formed on a base of a floor using a general coating floor material such as urethane, epoxy, or acrylic, a crack in the upper layer of the floor material due to a crack crack in the base layer of the coating floor material. It is well known to occur. Similar cracks may also occur in a floor material having a relatively high resistance, such as a polymer tile or a sheet, which is relatively resistant in consideration of crack followability as the underlayer. When cracks or breaks occur in these floor materials, not only the appearance is impaired, but also peeling occurs due to the entry of moisture from the cracked portions, which adversely affects the functionality of the floor. Also, an upper layer (waterproof material layer) made of urethane-based, acrylic-based, asphalt-based coating waterproof material or polymer roofing material on a cement mortar, cement concrete, asphalt mortar, or asphalt concrete substrate that forms the rooftop. However, there is a problem that cracks and fractures occur in the waterproof material layer due to crack cracks in the underlayer, which leads to water leakage, which is the most important as a waterproof layer, as in the above floor material. ing.
In this way, a common improvement method that does not cause cracks in the underlying layer to be laminated on the floor or rooftop, or even if it does occur, is not propagated to the floor material and waterproof material layer above it by some method or prescription. Has been done.

[0003]

DISCLOSURE OF THE INVENTION The present invention provides a building structure in which a resin material is laminated on a base, that is, a base forming a floor or a roof, and cracking cracks do not occur, and moreover, crushing of a fiber-reinforced resin molded product. Disposal as objects and rubber chips F
It is also intended that resources can be effectively used by reusing RP molded products and waste rubber.

[0004]

As a result of earnest research, the present inventors have found that a crushed material of thermosetting FRP or a mixture of the former and a rubber chip and a liquid thermosetting resin is applied on a floor base or a roof base. In addition to smoothing and smoothing the unevenness of the substrate, not only as a layer that imparts sound insulation and elasticity, but also by providing a floor material layer or a waterproof material layer on the layer, The present invention has been completed by finding that it is effective in absorbing cracks and cracks generated in the base substrate and preventing cracks and breakage of the flooring material layer and the waterproof material layer formed thereon. That is, the present invention provides (1) a crushed product (A) of a fiber-reinforced resin molded product as a main component, or a crushed product (A) of a fiber-reinforced resin molded product and a rubber chip (B) and a liquid as a binder on a substrate. A resin layer comprising the thermosetting resin (C), and then (2) a polymer material layer,
And the crushed product (A) of the fiber-reinforced resin molded product on the substrate,
Alternatively, a crushed product (A) of a fiber-reinforced resin molded product and a mixture of a rubber chip (B) and a liquid thermosetting resin (C) may be used in a thickness of 3 to 3.
Or to form a resin layer (1) and then to form a polymeric material layer (2) on it.
Alternatively, the present invention relates to a method for constructing a structure which comprises laying on a substrate a resin layer (1) and a polymer material layer (2) which are integrally molded in advance.

[0005]

BEST MODE FOR CARRYING OUT THE INVENTION In the present invention, a crushed product (A) of a fiber reinforced resin molded product as a main component, or a crushed product (A) of a fiber reinforced resin molded product and a rubber chip (B) and a liquid as a binder Although it is different from the resin layer (1) composed of the thermosetting resin (C), the crushed chips such as waste tires are treated with a synthetic resin emulsion or a resin resin emulsion (1) in Japanese Patent Publication No. 60-59379 or Japanese Patent Publication No. 2-26026. A layer solidified with urethane resin is used as a base layer. Their role as an underlayer placed on the base of the floor is to provide relief for the base, to provide sound insulation and elasticity.

Further, a waterproof layer is provided on a roof base made of cement mortar, cement concrete, asphalt mortar, or asphalt concrete, and the moisture contained in the base is vaporized due to the temperature rise, and the waterproof layer becomes an upper layer of the layer. There are many phenomena that the layers swell. However, in the field of rooftops and floors, when cracks are found in the base such as mortar, concrete, and ascon, the effect of the base adjustment, elasticity imparting, degassing, and crack buffering is obtained by hardening the elastic rubber chips as before. When used as a base adjustment layer (base layer) between the base and the upper layer as a layer having
There are problems in economy and load bearing. In the structure of the present invention,
It is more economical, has a load bearing property on the layer, and can protect the upper layer without following even if a crack occurs in the substrate.

The crushed product (A) of the fiber-reinforced resin molding used for forming the underlayer in the present invention is, for example, unsaturated polyester resin, vinyl ester resin, phenol resin, melamine resin, epoxy resin. A molded product of a thermosetting resin such as an acrylic resin or a thermoplastic resin. The fiber-reinforced resin molded article here is preferably, for example,
Radiation-curable unsaturated resin such as unsaturated polyester resin, vinyl ester resin, acrylic resin syrup (preferably a mixture of acrylic resin polymer or oligomer and acrylic monomer) is mixed with glass fiber reinforcement and cured. It is a molded product (hereinafter, FRP molded product). Preferred are unsaturated polyester resin glass fiber reinforced molded products. Moreover, as the crushed product (A) of the fiber-reinforced resin molded product, it is recommended that the product obtained from the waste of the above-mentioned molded product is used for effective use of resources. It also includes defective products.

The molded article (A) is preferably an oil fiber reinforced resin molded article obtained by press-molding a mixture of a fiber reinforced material and a thermosetting or thermoplastic resin, and a sheet molding compound (SMC). ) And bulk moldings (BMC). Further, preferably glass fiber reinforced molded product of radical curable unsaturated resin (FRP molded product), particularly preferably, glass fiber reinforced material and radical curable unsaturated resin such as vinyl ester resin, unsaturated polyester resin, acrylic resin and the like. It is a molded product of.

Specific examples of the thermosetting resin fiber reinforced molded product include, for example, printed circuit boards (epoxy resin), electric / electronic device parts (phenol resin), decorative boards (melamine resin), FRP (unsaturated polyester resin). , Vinyl ester resin, etc.) and the like.

As the general FRP molded product, for example, a bathtub, a bathroom panel, a waterproof pan, a vanity,
Washing balls, kitchen counters, septic tanks and other housing components,
Industrial parts such as pipes and water tanks, various electric parts, ships, small boats, automobile parts, helmets, mannequins,
Examples include chairs.

The fiber reinforcing material in the FRP molded product is an inorganic fiber such as glass fiber, metal fiber or ceramic fiber, and the average fiber length thereof is preferably 10 mm or less, more preferably 0. It is in the range of 1 mm to 5 mm. Particularly preferred is glass fiber. Further, the form of the fibers may be any of plain weave, satin weave, non-woven fabric, mat, glass roving and the like.

The crushing method may be any method, but it is preferable to use an inexpensive crushed piece that can be crushed by a commonly used crusher. At that time, it is not necessary to separate the composite material such as glass fiber. The crushed material is powdery,
It may be a fibrous, hijiki-like, plate-like or granular simple substance or mixture. Its size is powder, and the diameter of granules is 0.
05-20mm, length of thread, hijiki 1-20mm,
It is desirable that the plate-shaped diameter is 1 to 20 mm and the thickness is 0.5 to 10 mm.

Used tires used in the present invention and rubber chips (B) obtained by crushing industrial rubber products are, for example, natural rubber, polyisoprene rubber, styrene rubber, butadiene rubber, chloroprene rubber, butyl rubber, nitrile rubber, ethylene propylene. Examples thereof include rubber, EPDM, chlorosulfonated polyethylene, urethane rubber, acrylic rubber, and polysulfide rubber, which are pulverized rubber products such as tires and tubes produced from these. This shape can be obtained by using a rubber product manufactured by a known and commonly used machine, or a granular material having a particle size of 0.5 to 20 mm, preferably 1 to 10 mm, either alone or in combination. Can be used.

The thermosetting resin (C) is a liquid substance such as unsaturated polyester resin, urethane resin, phenol resin, melamine resin, epoxy resin, etc.
Unsaturated polyester resin and urethane resin are preferable in consideration of workability. The unsaturated polyester resin is a solution in which a styrene monomer or an acrylic monomer of unsaturated polyester is dissolved. A radical curing agent and a curing accelerator are added to this, and the mixture is cured at room temperature or by heating. The urethane resin may be a one-pack type of a urethane prepolymer resin having a free isocyanate group, or a two-pack type of a mixture of a urethane prepolymer resin and an active hydrogen compound which reacts with the urethane prepolymer resin.

A typical polyurethane resin as a binder will be described. It is liquid at room temperature and is an organic isocyanate compound such as 2,4-tolylene diisocyanate (TD).
Abbreviated as I), 65 / 35-TDI, 80 / 20-TD
I, 4,4 'diphenylmethane diisocyanate (MD
Abbreviated as I), dianisidine diisocyanate, tridene diisocyanate, metaxylylene diisocyanate,
Hexamethylene diisocyanate, phenylene diisocyanate, 1,5 naphthalene diisocyanate, polymethylene polyphenyl polyisocyanate, hydrogenated MD
I, an organic polyisocyanate compound selected from aromatic diisocyanates such as hydrogenated TDI, and alicyclic diisocyanates, or a polyol, preferably NCO, alone or in a mixture thereof.
/ OH equivalent ratio of 1.5 or more, more preferably a one-pack type consisting of NCO group-containing prepolymers reacted alone or in a mixture of 1.5 to 20 or by mixing with an active hydrogen compound that reacts with the isocyanate compound It is a two-part type.

The resin layer (1) which is laid evenly on the substrate of the present invention and cured is a crushed product (A) of a fiber reinforced resin molded product, or a crushed product (A) of a fiber reinforced resin molded product and a rubber chip. The weight ratio with (B) is preferably (A) :( B) =
10 to 100: 0 to 90 and a thermosetting resin (C)
Is preferably mixed in the layer in an amount of 5 to 30% by weight.

When the crushed product (A) of the fiber-reinforced resin molded product has a high mixing ratio, a rigid and solid layer is formed, and conversely the rubber chip is formed.
When the mixing ratio of (B) is high, the layer becomes elastic. That is,
The characteristics of rigidity and elasticity can be adjusted by appropriately changing this ratio depending on the application. Generally, an undercoating material having elasticity is preferably used as a base conditioning material for sports and amusement, and a material having rigidity is preferably used for a loading floor and applications where elasticity is not required.

The amount of the thermosetting resin (C) as a binder in the resin layer (1) is preferably 5 to 30% by weight, more preferably 10 to 25% by weight.

It is preferable that the resin layer (1) is so constructed as to have a fine porosity of 5 to 40% so that the effects of deaeration and insulation can be exhibited. This porosity can be adjusted by selecting the size of the crushed material (A) of the fiber-reinforced resin molded product and the granular material size of the rubber chips (B) to be used. The amount of thermosetting resin (C) used is 5 to 3
When it is 0% by weight, the porosity is in a preferable range, and the effects of degassing and insulation can be expected, which is advantageous in terms of weight reduction of the solidified body and economy. In addition, the adhesive force between the particles is high, and the solidified product becomes stronger.

In the resin layer (1) of the present invention, in addition to the crushed material (A) and the rubber chips (B) of the fiber reinforced resin molding, pebbles and mineral inorganic materials can be mixed and used. In order to achieve the above target, it is preferable to use one that does not require separation at the time of disposal. As a material that can be mechanically mixed by a conventional mixing device such as a nider or a mixer, granules and crushed materials mainly composed of an organic material are preferable, and examples thereof include plastics, wood chips, straws and the like. The integrated resin layer (1) and polymer material layer (2) according to the present invention does not require separation at the time of disposal and can be crushed again for use in the present invention. It is preferable to use a recyclable recycled product that can be used as a raw material for the cement and steel industries.

As the material of the polymer material layer (2) formed on the resin layer (1) in the present invention, those generally used as a waterproof material or floor material to be applied or stuck are preferable. , Asphalt, coating type of polymer material type (including rubber type), sheet, tile type,
The coating type is particularly preferable. Typical waterproofing materials are urethane-based waterproofing materials, acrylic rubber-based waterproofing materials, and FRP waterproofing materials, and flooring materials are urethane-based, epoxy-based, and radical-curable vinyl ester resins, unsaturated polyester resins, acrylic resins. Etc. are typical.

In the present invention, when the polymer material layer (2) is applied on the resin layer (1), the polymer material layer (2) is easy to apply and has a uniform film thickness and excellent finish. In order to secure the property, a method of forming a dense layer on the surface layer portion of the resin layer (1) can be adopted. As a method for forming the surface layer denseness of the resin layer (1), it is preferable to apply a surface layer sealing material that fills only the irregularities of the surface layer portion without filling the internal voids.

As the sealing material, fine particles of the crushed material (A) and / or the rubber chips (B) of the fiber reinforced resin molding are selected and used, and the liquid thermosetting resin (C) is used as a binder. The mixture can be used as a sealing material.

Further, the surface of the resin layer (1) can be coated with a tack coat or a primer for improving the adhesive force with the polymer material layer (2). Generally, as the tack coat and the primer, a solution type of a moisture curable urethane resin or an epoxy resin can be used.

The thickness of the resin layer (1) in the present invention is 3 to 10.
0 mm is suitable, and is appropriately selected depending on the application and effect. The thickness of the polymer material layer (2) is preferably 1 to 10 mm in the case of a waterproof material, generally 2 to 5 mm, and 0.5 to 5 mm in the case of a floor material. It is suitable, and generally 1 to 3 mm is preferable.

Regarding the construction method of the structure of the present invention, a crushed product (A) of the fiber reinforced resin molded product, or a crushed product (A) of the fiber reinforced resin molded product and a rubber chip (B) on the substrate are in liquid form. Mix the mixture with thermosetting resin (C) to a thickness of 3 to 100 m.
m and then cured to form the resin layer (1) and then form the polymer material layer (2), or the resin layer (1) and the polymer material layer (2) are integrated in advance. This can be done by laying the molded product on the base.

When the polymer material layer (2) is a waterproof material, the structure of the present invention can be applied to new construction and repair of general flat roofs, balconies, balconies, etc. as a purpose of exerting a waterproof effect. Further, when the polymer material layer (2) is a flooring material, it can be applied to new construction and renovation of gymnasiums, playgrounds, sports gyms, rooftop / indoor parking lots and the like.

According to the present invention, it is possible to solve problems such as pollution caused by incineration of waste rubber and waste FRP moldings and land securing by landfill disposal, and waste thermosetting properties such as waste rubber and FRP moldings. This brings the advantage that plastics can be used as a raw material.

That is, rubber and plastics as wastes are collected and reused to some extent in a single unit, but most of the plastics are incinerated, or finally disposed of by landfill. There is. Waste rubber and plastics are a social problem because black smoke, toxic gas or dioxins are generated when incinerated. Further, the combustion temperature at the time of incineration is high, which shortens the life of the incinerator. Although some of the waste tires have already been recycled as raw materials for cement production, it is ideal to recycle them into shapes by material recycling. Since glass fibers remain after incineration, the FRP molded product is mainly crushed, and it is considered appropriate for landfill disposal. Accompanying this, securing landfill sites for waste has become a problem. Conventionally, as a method for recycling a waste FRP molded product, there are a method of finely pulverizing and collecting as a filler and a method of separately collecting into a monomer, glass fiber and the like by chemical recycling, but both of them are not practical because of high cost.

As a means for solving the above problems, the present invention is capable of reusing wastes of rubber and fiber reinforced resin moldings, so that pollution caused by incineration of waste plastics and land securing by landfill disposal, etc. The problem of can be solved. Further, the structure of the present invention can be effectively incinerated as it is, for example, as a raw material for cement if it is crushed to an appropriate size after the portion consisting of the resin layer (1) and the polymer material layer (2) is crushed. It is also one that can respond to a recycling-based society that can.

[0031]

EXAMPLES The present invention will now be described in more detail by way of examples, which should not be construed as limiting the invention thereto. Unless otherwise specified, "part" and "%" in the text are based on weight.

(Example 1) 8 mm of a crushed product of an FRP bus unit molded product made of beige unsaturated polyester resin
300 parts of sieve passed product, grain diameter of waste tire rubber 1-3 mm
In a mixture of 100 parts of the rubber chips of No. 1, a one-component Pandex TP-1221 (manufactured by Dainippon Ink and Chemicals, Incorporated) of a urethane prepolymer containing an NCO group in the molecule is used.
Parts were sequentially added and mixed at room temperature for about 5 minutes using a simple mixer for mortar mixing until uniform.

A solution prepared by previously mixing Pandex TP-1221: ethyl acetate = 80: 20 on the base concrete in a weight ratio of 300 g / m as a tack coat.
Immediately after application with a roller brush of No. ² , the mixture of the above-mentioned crushed material and granules was spread on it so as to have a thickness of 10 mm, and left to stand at room temperature for 15 hours to be completely cured.
A beveled unsaturated polyester resin FRP bus unit molded product crushed on the layer as a sealing layer 4 m
m sieve passed product: Pandex TP-1221 = 300:
The mixture mixed at a ratio of 80 was applied by rubbing with a 1 kg / m ² metal trowel, and left standing at room temperature for 15 hours for curing to form an underlayer. A publicly known urethane-coated floor material was applied onto the ground layer (base adjustment layer) constructed by the above operation to form a floor material layer to obtain a structure. The urethane-coated floor material layer was composed of a urethane-coated floor material (thickness: 2 mm) having a hardness of 90 (Shore hardness A) and a primer in this order from the top. The obtained floor (structure) had excellent walking feeling and aesthetics.

(Example 2) White kitchen counter (artificial marble-like) molded product made of thermosetting resin BMC, 300 parts of 12 mm sieve-passed product, beige unsaturated polyester resin FRP bath unit molded product As a crushed product, 200 parts of 8 mm sieve passed product, 100 parts of Polylite PM400 (manufactured by Dainippon Ink and Chemicals, Inc.) with 0.2% 6% cobalt naphthenate, curing accelerator Permek N (Nippon Yushi ( (Manufactured by K.K. Co., Ltd.), and then uniformly mixed for about 5 minutes.

Moisture-curing urethane primer "Polylite PD (manufactured by Dainippon Ink and Chemicals Co., Ltd.)" was applied on a concrete substrate in advance with a brush at 200 g / m ² and cured and dried at room temperature for about 3 hours. The above mixture is used as an undercoat layer on the surface of which the thickness is 20 m using an iron pressure roller.
It was laid so that it would be m. The pavement was fully cured after about 5 hours at room temperature.

As a sealing layer on that layer, 0.2% of 6% cobalt naphthenate was added to 400 parts of a crushed product of a beige-colored unsaturated polyester resin FRP bath unit molded product passing through a 4 mm sieve. 100 parts of Polylite PM400 and 1.5 parts of curing accelerator Permek N were added in that order and uniformly mixed for about 5 minutes, and the mixture was rubbed with a 1.5 kg / m ² metal trowel, and left at room temperature for 15 hours. Cured. A publicly known urethane waterproof material was applied on the underlayer adjusting layer constructed by the above-mentioned operation to form a waterproof layer, thereby obtaining a structure. The urethane waterproof material layer is an acrylic urethane paint layer and JISA6021 (construction coating waterproof material standard) from the top.
It is composed of a conformable urethane waterproof material layer (thickness 3 mm) and a primer layer in this order. The resulting structure had excellent aesthetics and surface smoothness.

[0037]

INDUSTRIAL APPLICABILITY The present invention provides a building structure in which cracks and cracks do not occur even when a resin material is laminated on a substrate, and moreover, as a crushed product of a fiber reinforced resin molded product or as a rubber chip, a waste FRP molded product and waste rubber. Resources can be effectively used by reusing.

   ─────────────────────────────────────────────────── ─── Continued front page    F term (reference) 4F100 AK01B AK01C AK25B AK44B                       AK51B AK51C AK53B AN00B                       AN00C AT00A BA03 BA07                       BA10A BA10C DE01B DH02B                       GB07 JB16B JK20 JL16                       JL16B

Claims (8)

[Claims] 1. A crushed product (A) of a fiber reinforced resin molded product as a main component, or a crushed product (A) and a rubber chip (B) of a fiber reinforced resin molded product and a liquid as a binder on a substrate. A structure comprising a resin layer comprising a thermosetting resin (C), and then (2) a polymer material layer. 2. In the resin layer (1), the weight ratio of the crushed material (A) and the rubber chip (B) of the fiber reinforced resin molding is
The structure according to claim 1, wherein (A) :( B) = 10 to 100: 0 to 90 and the content of the thermosetting resin (C) is 5 to 30% by weight. 3. The structure according to claim 1 or 2, wherein the crushed product (A) of the fiber reinforced resin molded product is a crushed product of the fiber reinforced molded product of the thermosetting resin. 4. The structure according to claim 1, wherein the liquid thermosetting resin (C) is an unsaturated polyester resin, a urethane resin, an epoxy resin or an acrylic resin. 5. The structure according to claim 1, wherein the base is a base for forming a floor. 6. The structure according to claim 1, wherein the base is a base for forming a rooftop. 7. The structure according to claim 1, wherein the polymer material layer (2) is a resin or rubber floor material, or a resin or rubber waterproof material. 8. A crushed product (A) of a fiber reinforced resin molded product, or a crushed product (A) of a fiber reinforced resin molded product and a rubber chip (B) and a liquid thermosetting resin (C) on a substrate. The mixture is applied to a thickness of 3 to 100 mm and cured to form a resin layer (1).
And then forming a polymeric material layer (2) on it, or laying on the substrate a resin material (1) and a polymeric material layer (2) that have been previously integrally molded. Method of constructing a structure consisting of.