JP2005344320A - Resin concrete product and manufacturing method therefor - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a resin concrete product which can be used for various purposes such as a paving material, requiring draining characteristics, and internal and external finishing materials, a ceiling material and a flooring tile material for a building, requiring lightweight properties, and a manufacturing method for the resin concrete product. <P>SOLUTION: This resin concrete product includes many pieces (12) which are bonded to one another with a void (16) by means of a binder (14) and composed of foamed glass, and some of the small pieces are partially covered with the binder (14). <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a resin concrete product suitable for use as a paving material, a building interior / exterior material, a ceiling material, a floor tile material, and the like, and a method for producing the same.

  Conventionally, suitable for use as a paving material, a base layer made of a large number of sand-like granular materials bonded to each other with a binder, and bonded to each other with a binder laminated on the base layer. Resin concrete products having a surface layer composed of small pieces such as rubber chips and cork chips have been proposed.

Japanese Patent Laid-Open No. 7-138061

  According to this resin concrete product, the rigidity of the base layer helps to maintain the shape as a paving material, and the elasticity of the surface layer gives a pedestrian a cushioning property that reduces the impact. Furthermore, the space | gap between the granular materials and between small pieces in the said base layer and surface layer provides water permeability.

  By the way, the water permeability of the conventional resin concrete product contributes to preventing the occurrence of water pools on the road surface, but the lack of water retention is due to the reflection of sunlight from the road surface in summer and the accompanying walking. Causes discomfort.

  In addition, the conventional resin concrete product is made of sand and the constituent particles of the base layer are made of sand in order to give rigidity to other uses, for example, building interior and exterior materials that are required to be lightweight, It is difficult to turn to applications such as ceiling materials and floor tile materials.

  An object of the present invention is to provide a resin concrete product that can be used for various purposes such as a paving material, an interior / exterior material of a building that requires lightness, a ceiling material, a floor tile material, and the like, and a method for producing the same. .

  The present invention relates to a resin concrete product, and includes a plurality of small pieces made of cellular glass, which are bonded to each other with a binder and are partially covered by the binder. Including.

  Further, another resin concrete product according to the present invention is a large number of small pieces made of cellular glass bonded to each other with a binder, and a part of these is partially covered with the binder. And a surface layer made of a large number of rubber chips, wooden chips or cork chips, which are laminated on the base layer and bonded by a binder. Any resin concrete product may include a reinforcing material made of a glass cloth, a glass nonwoven fabric, or a metal or plastic net embedded between a large number of small pieces. Further, a large number of rubber chips, wooden chips, or cork chips may be bonded to each other with a gap therebetween.

  This resin concrete product is made up of a large number of chips made of rubber chips, wooden chips or cork chips, and a large number of chips coated with a binder sufficient to bond them together with a gap between them. A large number of small pieces made of cellular glass, bonded to each other with a gap between them, and coated with a sufficient amount of a binder to partially cover these parts, It can be obtained by spreading on a large number of chips, applying hot pressure to these chips and small pieces to form the large number of chips and the small pieces in layers, and then demolding. A reinforcing material made of a glass cloth, a glass nonwoven fabric, or a metal or plastic net can be disposed on the multiple chips, on the multiple small pieces, or between the multiple small pieces.

  As the binder, a thermosetting resin or a thermoplastic resin can be arbitrarily selected. When a binder made of a thermoplastic resin is selected, it is desirable to apply a primer to the surface of the numerous chips spread out in the mold.

  According to the present invention, since a large number of small pieces constituting a resin concrete product are made of a relatively lightweight cellular glass and are bonded with a gap between each other, the resin concrete product obtained can be reduced in weight. Can do. For this reason, the said resin concrete product can be used for many uses, such as the interior / exterior material of a building in which lightweightness is calculated | required, a ceiling material, and a floor tile material. In addition, the resin concrete product composed of a large number of small pieces of cellular glass has a relatively high rigidity, and the gap between the small pieces gives water permeability to the resin concrete product, so that it is used as a paving material. Can do. When a reinforcing material is embedded between a large number of small pieces, the rigidity of the resin concrete product can be further increased.

  In resin concrete products in which a large number of small pieces made of cellular glass are used as a base layer, and a surface layer made of rubber chips, wooden chips or cork chips is laminated thereon, the texture, color, etc. of the surface layers have a decorative effect. Demonstrate.

  In the case where a large number of chips on the surface layer of the resin concrete product having the base layer and the surface layer are bonded to each other with a space between them, the small pieces of cellular glass of the base layer are also bonded to each other with a space therebetween. Has water permeability. Further, since some of the small pieces of the bubble glass are partially covered by a binder that couples them, water flowing through the gaps of the small pieces penetrates into the inside from the exposed surface, Retained. For this reason, when the resin concrete product is used as a paving material, the resin concrete product as the paving material provides good drainage with water permeability, and the water retention property reduces the reflection of sunlight due to moisture evaporation. The rigidity of the base layer contributes to maintaining the flatness of the walking road surface, and since the surface layer has elasticity, it helps to reduce the impact during walking.

  The resin concrete product having the base layer and the surface layer can be obtained by the production method according to the present invention.

  Referring to FIG. 1, a resin concrete product according to the present invention is indicated generally by the numeral 10.

  The illustrated resin concrete product 10 has a plate shape as a whole and includes a large number of small pieces 12 made of cellular glass.

  As shown in FIG. 2, these small pieces 12 are bonded to each other with a gap 14 by a binder 14, and the small pieces 12 made of cellular glass have a smaller specific gravity than sand particles. For this reason, the resin concrete product 10 is relatively light and has a relatively high mechanical strength. Thus, the resin concrete product 10 is suitable for use as a building exterior material, interior material, ceiling material, floor tile material, and the like that are required to be lightweight.

  The resin concrete product 10 has water permeability or air permeability that allows water or air to flow through the gaps between the small pieces. Furthermore, these small pieces 12 consist of a mixture of what is entirely covered by the binder 14 and what is partially covered, and one of the surfaces of the small pieces 12 partially covered by the binder 14. The part is exposed to the atmosphere. Moreover, the small piece 12 made of cellular glass has a large number of hollow portions 18 opened on the surface thereof. Thus, the small piece 12 can receive and hold water or air through the opening in its exposed surface into the hollow portion 18 therein. Therefore, the resin concrete product 10 can be used as a pavement material laid on a sidewalk or a park where drainage is required, and is held by the small pieces 12 when used as a pavement material. The evaporation of the water and the release of water vapor into the atmosphere through the small pieces 12 can alleviate the reflection of direct sunlight on the road surface.

  FIG. 3 shows a resin concrete product 20 of another example. This product 20 includes a base layer 22 made of the same resin concrete product as shown in FIG. 1, and a surface layer 24 laminated on one of both sides of the base layer.

  The surface layer 24 includes a number of chips 26 made of rubber chips, wooden chips or cork chips bonded together with a gap (not shown) therebetween. Therefore, the surface layer 24 also has water permeability or air permeability. Further, the tip 26 can be elastically deformed toward the gap when receiving a load.

  The resin concrete product 20 can also be used for interior and exterior materials of the building, ceiling materials, floor tile materials, paving materials, and the like. When the surface layer 24 is used as an interior / exterior material of the building, a ceiling material, a floor tile material, or the like, instead of the illustrated example, there are no air gaps between a large number of chips 26, water permeability or air permeability. May not be included.

  When the resin concrete product 20 is used as a paving material, the drainage of the road surface can be ensured by the water permeability of both layers 22 and 24. Further, the water retention of the small pieces 12 made of cellular glass similarly reduces the reflection of the road surface in summer.

  A number of the chips 26 have a particle size smaller than the bubble glass piece 12 in the base layer 22. By using the chip | tip 26 with a small particle size, the roughness of the eyes in the surface layer 24 can be made finer. The texture depending on the type of the chip 26, the color of the chip 26, and the like impart decorativeness to the resin concrete product 20, and the elasticity of the chip 26 imparts cushioning properties.

  The thickness dimension of the base layer 22 and the thickness dimension of the surface layer 24 can be set, for example, within a range of 10 to 100 mm and within a range of 5 to 20 mm, depending on the application. The size (length) of the small piece 12 of foam glass is set in the range of 5 to 20 mm, for example, and the width and length of the chip 26 are set in the range of 3 to 5 mm and in the range of 3 to 30 mm, respectively. be able to.

  The resin concrete products 10 and 20 can have a reinforcing material 28 made of a glass cloth, a glass nonwoven fabric, or a metal or plastic net embedded in the resin concrete product 10 or 20, thereby increasing its rigidity. .

  In the resin concrete product 20 shown in FIG. 3, a reinforcing material 28 is embedded between a large number of small pieces 12 of the base layer 22. In the resin concrete 10 shown in FIG. 1, similarly, a reinforcing material 28 can be embedded between a large number of small pieces 12.

  The resin concrete product 20 can be manufactured as follows.

  First, foam glass is manufactured. The foamed glass is obtained by crushing waste glass such as a glass bottle into a powder form using a mill (not shown). A foaming material is added to the obtained glass powder, and this is heated to 1000-1200 degreeC in a furnace. Thereby, the said glass powder can be heat-melted and this can be made to foam. The material thus obtained is then cooled and solidified to obtain foamed glass. Next, this foamed glass is pulverized to obtain small pieces 12.

  The small piece can also be obtained by purchasing a commercially available foamed glass instead of producing the foamed glass and pulverizing it.

  Next, in order to obtain a material for forming the base layer 22, a large number of small pieces 12 and a thickened thermosetting resin (for example, polyurethane, polyester, epoxy, phenol, polyamide, etc.) as the binder 14 are put into a mixer. Stir for 5-10 minutes.

  The amount of the thermosetting resin is 30 to 70% by weight with respect to the amount of the small pieces 12. Thickening of the thermosetting resin can be performed by adding a thickener (for example, calcium carbonate, silica, talc, etc.) to the thermosetting resin and stirring. The amount of the thickener is 10 to 100% by weight with respect to the thermosetting resin. As a result of the agitation, all or part of the surface of the small piece 12 is covered with the binder 14.

  Next, a number of other new small pieces 12 are added to the mixer containing the small pieces 12 covered with the binder 14 and stirred for about 1 minute. The input amount of the other small pieces 12 is 0.5 to 1.5 times the weight of the previously input small pieces 12.

  Thereby, a part of binder 14 adhering to the small piece 12 thrown previously adheres to a part of surface of the small piece 12 thrown later. As a result, a mixture of small pieces 12 entirely covered by the binder 14 and partially covered small pieces 12 which are bonded to each other by the binder 14 at intervals is obtained. The amount of the thermosetting resin as the binder 14 is sufficient for the amount of the small pieces 12 to bond the small pieces 12 with gaps between them and partially cover these parts. It can be said.

  As the binder 14, a thermoplastic resin (for example, polyethylene, polystyrene, polypropylene, ABS, or the like) can be used instead of the thermosetting resin.

  In this case, first, a large number of small pieces 12 are heated to about 250 ° C. using, for example, a rotary kiln (not shown). Next, after the heated pieces 12 are put into a mixer, a thermoplastic resin in an amount of 30 to 100 parts by weight with respect to the amount of the pieces is added little by little to the mixer and stirred. The thermoplastic resin is heated and melted by touching the heated small piece 12, and all or a part of the surface of the small piece 12 is covered with the molten thermoplastic resin.

  Next, another new piece 12 in an amount of 0.5 to 1.5 times the weight of the piece 12 initially charged is further added to the mixer and stirred for about 1 minute. As a result, a mixture of small pieces 12 partially covered by the binder 14 and small pieces 12 that are completely covered and bonded by the binder 14 at intervals is obtained. Such a set amount of the plastic resin is also an amount sufficient for the amount of the small pieces 12 to bond the small pieces 12 with gaps therebetween and partially cover these parts.

  In order to obtain the surface layer 24, a large number of chips 26 and these binders are stirred and mixed for about 10 minutes using the mixer. As a result, the entire surface of the chip 26 or a part thereof is covered with the binder.

  When the chip 26 is a rubber chip, 5 to 15 parts by weight of a one-component polyurethane resin can be used as the binder with respect to the amount of the chip. When the chip 26 is a wooden chip, a mixture of 20 to 70 parts by weight of a one-component polyurethane resin, 50 to 100 parts by weight of a polyester resin, and 30 to 70 parts by weight of phenol with respect to the amount of the chip. Can be used. When the chip 26 is a cork chip, 10 to 30 parts by weight of a one-component polyurethane resin can be used with respect to the amount of the chip. As a result, a large number of chips 26 are bonded to each other with the binder therebetween.

  However, as the binder, an adhesive or reactive material that can be bonded to the binder 14 in the base layer 22 is selected. Such a set amount of the binder is an amount sufficient to bond these chips with gaps to each other with respect to a large number of chips. However, instead of this example, a larger amount of binder can be used so that a large number of chips are filled with the binder, that is, there are no gaps between the chips.

  Referring to FIG. 4, the mixture of the chip 26 and the binder is spread inside a box-shaped mold 30. When the binder is made of a thermoplastic resin, a primer is applied to the spread surface of the mixture by spraying or the like. As the primer, a material having a common adhesive property (for example, rubber-based or urethane-based) that can be bonded between the binder in the base layer 22 and the binder in the surface layer 24 is selected.

  Next, a mixture of the small pieces 12 and the binder 14 is spread on the mixture and leveled. The reinforcing material 28 is placed at a height position below or in the middle of the layer made of the mixture as necessary.

Next, a lid 32 is placed on the mold 30, and a pressure of 3 to 5 kg / cm ² is applied to the mixture in the mold 30 through the lid. Under this pressurization, the mixture 30 is heated to 120 to 180 ° C. by heating the mold 30 and the lid 32 in a press or in an electric furnace. As a result, the thermosetting resin as a binder is cured, or the thermoplastic resin is softened, and the binder of the base layer 22 and the binder of the surface layer 24 are bonded to each other. Thereby, the mixture is formed into a layer.

  Thereafter, after the formed mixture is cooled, a pallet 34 arranged in advance at the bottom of the mold 30 is inserted into a rod (not shown) from a hole 36 formed in the bottom of the mold 30, and the mold 30 is inserted. In contrast, the pallet 34 is lifted to remove the mold. Thereby, the resin concrete product 20 is obtained.

  When manufacturing the resin concrete product 10 which does not have the surface layer 24, only the mixture of the small piece 12 and the binder 14 is spread | laid in the metal mold | die 30, and it levels. Then, the resin concrete product 10 can be obtained by performing the same process as in the manufacture of the resin concrete product 20.

1 is a side view schematically showing a resin concrete product according to the present invention. It is a partial expanded sectional view of the resin concrete product shown in FIG. It is a side view which shows schematically the other resin concrete products which concern on this invention. It is a schematic longitudinal cross-sectional view of the material for manufacturing the resin concrete which concerns on this invention, and the metal mold | die in which this was put.

Explanation of symbols

10, 20 Resin concrete product 12 Small piece 14 Binder 16 Cavity 22, 24 Base layer and surface layer 26 Chip 28 Reinforcement material 30 Mold

Claims (8)

  A resin concrete product comprising a large number of small pieces of cellular glass, which are bonded to each other by a binder, each of which is partially covered by the binder.   A base layer including a plurality of small pieces made of cellular glass bonded to each other by a binder, each of which is partially covered by the binder, and laminated on the base layer. A resin concrete product comprising a large number of rubber chips, wooden chips or cork chips that are bonded to each other by a binder.   Furthermore, the resin concrete product of Claim 1 or 2 containing the reinforcing material which consists of a glass cloth, a glass nonwoven fabric, or a metal or plastic net embed | buried between the said many small pieces.   The resin concrete product according to any one of claims 1 to 3, wherein a plurality of rubber chips, wooden chips, or cork chips on the surface layer are bonded to each other with a gap therebetween. A number of chips made of rubber chips, wooden chips or cork chips, each coated with an amount of a binder sufficient to bond them together with a gap between them, and placed inside a box-shaped mold,
A large number of small pieces made of cellular glass, which are bonded to each other with a gap between them and coated with a sufficient amount of a binder to partially cover them, a large number of chips in the mold Leveling on the top,
Applying hot pressure to the chips and the small pieces to form the multiple chips and the small pieces in layers;
Then, the manufacturing method of the resin concrete product including demolding.   The manufacturing method of Claim 5 including arrange | positioning a glass cloth, a glass nonwoven fabric, or a metal or plastic net | network on the said chip | tip, the said many small piece, or this small piece.   The manufacturing method according to claim 5, wherein the binder is made of a thermosetting resin.   The manufacturing method according to claim 5, wherein the binder is made of a thermoplastic resin, and includes applying a primer to the surface of the multiple chips prior to spreading the multiple pieces on the multiple chips. Method.

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