JP2015094074A - Deck material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a deck material capable of being used outdoors for a long period of time.SOLUTION: A deck material 1 uses artificial marble as a base material 2. A silicone resin layer 3 containing an ultraviolet light reduction material is formed over the surface of the base material 2.

Description

  The present invention relates to a deck material.

  Natural wood is often used as a base material for deck materials constituting floors such as verandas, balconies, and terraces. Natural wood is prone to cracking, warping, thinning, gaps, fluffiness, flaking, discoloration, etc. due to repeated drying and wetting. In addition, depending on the installation environment, there is a concern that the quality will not be stable over a long period of time because there are concerns about the generation of pests such as termites, mold, and algae. Therefore, floor materials and floor panels using artificial marble as a base material have been proposed so far (see, for example, Patent Document 1-2).

JP 2001-12065 A Japanese Utility Model Publication No. 62-131536

  Artificial marble is widely used in kitchens, bathrooms, furniture, etc. because of its excellent design, heat resistance, chemical resistance, and processability. However, since there are problems in weather resistance such as yellowing and deterioration due to ultraviolet rays, there are restrictions on outdoor use.

  The present invention has been made in view of the circumstances as described above, and an object thereof is to provide a deck material that can be used outdoors for a long period of time.

  In order to solve the above-mentioned problems, the deck material of the present invention is characterized in that a layer of a silicone resin containing a UV-cutting agent is formed on the surface of a plate-like substrate formed of artificial marble. To do.

  In this deck material, the artificial marble is preferably a vinyl ester artificial marble.

  Further, this deck material preferably has a foot portion for fixing the base material.

  According to the deck material of the present invention, it can be used outdoors for a long time.

It is the schematic diagram which showed one Embodiment of the deck material of this invention.

  An embodiment of a deck material of the present invention will be described with reference to the drawings. FIG. 1 is a schematic view showing an embodiment of the deck material of the present invention. 1A is a cross-sectional view, FIG. 1B is a view from the front side, and FIG. 1C is a view from the back side.

  In the deck material 1 of FIG. 1, a layer 3 of a silicone resin (hereinafter, also simply referred to as a silicone resin layer) containing a UV-cutting agent is formed on the surface of a plate-like substrate 2 made of artificial marble. ing.

  As a shape of the base material 2, for example, as shown in FIG.

  The artificial marble forming the substrate 2 is configured as a molded body of a resin composition mainly containing a thermosetting resin and an inorganic filler.

  Examples of the thermosetting resin include vinyl ester resins, unsaturated polyester resins, and acrylic resins. Among these, vinyl ester resins are excellent in water resistance and toughness. For this reason, artificial marble (vinyl ester artificial marble) formed using a vinyl ester resin is preferably used as the substrate.

  Examples of vinyl ester resins include bisphenol type vinyl ester resins and novolac type vinyl ester resins. These may be used alone or in combination.

  The inorganic filler is blended in order to give the base material 2 a texture, strength, and the like. Specific examples of inorganic fillers include calcium silicate, talc, silica, calcium carbonate, aluminum hydroxide, magnesium hydroxide, calcium sulfate, barium sulfate, talc, clay, alumina and other ceramic particles, mica and sandstone Particles and the like. These may be used alone or in combination.

  The inorganic filler preferably has an average particle size in the range of 0.1 to 200 μm, and particularly preferably in the range of 1 to 100 μm. By using an inorganic filler having an average particle diameter in the range of 0.1 to 200 μm, the impact resistance strength of the substrate can be improved. Moreover, the viscosity increase of a resin composition can be suppressed and handling workability | operativity can also be improved. The average particle diameter can be obtained as a median diameter (d50, volume basis) by cumulative distribution from a measured value of particle size distribution by a laser diffraction / scattering method using a commercially available laser diffraction / scattering particle size distribution measuring apparatus. it can.

  The inorganic filler may be used as it is, or may be used after being treated with a silane coupling agent or the like. It is preferable to treat with a silane coupling agent because the adhesion between the resin and the inorganic filler and the adhesion between the substrate 2 and the silicone resin layer 3 formed on the surface thereof can be improved.

  An inorganic filler is mix | blended within the range of 10-400 mass parts with respect to 100 mass parts of thermosetting resins, for example. Thereby, the texture, strength, etc. can be further improved.

  The resin composition may contain a crosslinking agent such as a styrene monomer or an acrylic monomer. In addition, additives such as a pattern material, a colored toner, an internal release agent, a curing agent, and an initiator may be blended. These additives may be appropriately selected and used depending on the type of the thermosetting resin, the curing temperature, the mold and the like.

  In order to form the base material 2 using the resin composition described above, cast molding in which the resin composition is poured into a mold and solidified may be applied. Hot press molding and extrusion molding can also be applied. After the base material obtained by molding is cut into the shape of the target commercial product, it is preferable to perform surface polishing. By performing the surface polishing process, not only the design of the substrate 2 itself is enhanced, but also the adhesion with the coating film (silicone resin layer 3) applied thereafter can be improved.

  The layer 3 of the silicone resin can be formed as a coating film by coating the surface of the substrate 2 with a coating resin composition having a silicone resin or a compound capable of forming a silicone resin and an ultraviolet blocking agent and curing the coating resin composition.

  Examples of the silicone resin or a compound capable of forming a silicone resin included in the coating resin composition include organoalkoxysilane, a partially hydrolyzed product thereof, and a polymer of organoalkoxysilane. From the viewpoint of durability, such as strength, it is preferable to use a mixture of at least one compound selected from these and a polymer.

  Examples of the ultraviolet blocking agent that the coating resin composition has include metal oxide-based inorganic ultraviolet absorbers such as titanium oxide, zinc oxide, and cerium oxide. Moreover, organic ultraviolet absorbers, such as a benzotriazole type, a benzophenone type, a cyanoacrylate type, a salicylic acid ester type, are also mentioned. The organic ultraviolet absorber may be used in combination with a hindered amine light stabilizer. In order to provide long-term weather resistance, it is preferable to use an inorganic ultraviolet absorber.

  The UV screening agent is preferably blended, for example, in the range of 5 to 50 parts by mass, more preferably 20 to 100 parts by mass with respect to 100 parts by mass of the silicone resin or the compound capable of forming the silicone resin in the coating resin composition. It is within the range of 30 parts by mass. Thereby, the weather resistance can be further improved.

  The coating resin composition includes a curing catalyst, an antibacterial agent, an antifungal agent, a matting agent, an antifoaming agent, a thickening agent, an anti-settling agent, a leveling agent, and a dispersing agent in order to improve coating film properties and paintability. Further, a heat stabilizer, a wax component, a solvent component and the like may be blended.

  The thickness of the silicone resin layer 3 formed by coating the substrate 2 with the coating resin composition is desirably a thickness that can shield 90% or more of ultraviolet rays. Specifically, it is preferably 1 to 30 μm. By coating the coating resin composition on the substrate 2 so that the thickness of the silicone resin layer 3 is 1 to 30 μm, it is possible to reduce the occurrence of unpainted portions and uneven coating. In addition, it is possible to suppress the deterioration of design properties and the occurrence of cracks.

  The frequency | count of application | coating to the base material 2 of a coating resin composition does not have a restriction | limiting in particular, One time or 2 times or more may be sufficient. A conventionally well-known method is mentioned as an application | coating system. For example, a method using a flow coater, roll coater, curtain coat, knife coat, spin coat, table coat, sheet coat, single wafer coat, die coat, or bar coat. Further, a spraying method, an airless spray method, an air spray method, a brush coating, a trowel coating, a dipping method, a pulling method, or the like may be used. It may be applied automatically by these methods, or may be applied manually.

  In this way, a deck material 1 is obtained in which a layer 3 of a silicone resin containing an ultraviolet blocking agent is formed on the surface of a plate-like substrate 2 made of artificial marble. Since this deck material 1 has a silicone resin layer 3 containing an ultraviolet light-cutting agent formed on the surface thereof, it is excellent in weather resistance and can be used outdoors for a long time.

  The deck material 1 has a scaffold 10 for fixing the base material 1 as shown in FIG. 1 in order to facilitate installation on the ground and to make it easy to construct a floor by arranging a plurality of sheets in a plane. You may do it.

  The foot part 10 has a base material installation part 11 on which the base material 2 can be installed and fixed. The base material installation part 11 has a side wall 12 in the periphery so that the base material 2 can be fitted and installed, and a bottom wall 13 formed in a substantially X-shaped lattice shape on the bottom surface. Engagement pieces 14 that can be connected to the foot 10 of the adjacent deck material 1 are formed on the side wall 12 on the outside. The bottom wall 13 is formed with a fixing tool insertion portion 15 into which a fixing tool such as a screw for fixing the scaffold 10 and the base material 2 can be inserted at a portion intersecting in a substantially X shape.

  When fixing the base material 2 to the scaffold 10, first, the base material 2 is fitted from above the base material setting portion 11 of the scaffold 10, and the back surface of the base material 2 is brought into contact with the bottom wall 13. Next, the scaffold 10 and the substrate 2 are fixed by inserting the fastener into the anchor insertion portion 15 from below the anchor insertion portion 15 of the scaffold 10 and screwing it into the substrate 2. In this way, the deck material 1 in which the base material 2 is fixed to the scaffold 10 is obtained. By arranging a plurality of deck materials 1 in a plane and engaging the engaging pieces 14 of the adjacent deck materials 1 together, the deck materials 1 can be connected to form a floor such as a veranda, a balcony, or a terrace. .

  EXAMPLES Hereinafter, although an Example demonstrates this invention further in detail, this invention is not limited to these Examples at all.

<Example 1>
One part by mass of a curing agent (Perocta O / manufactured by Nippon Oil & Fats Co., Ltd.) was added to 100 parts by mass of vinyl ester resin (Neopol 8101 / manufactured by Nippon Iupika Co., Ltd.) and stirred for a predetermined time. Thereafter, 200 parts by mass of aluminum hydroxide (CW-310SH, manufactured by Sumitomo Chemical Co., Ltd.) as an inorganic filler was added to 100 parts by mass of the vinyl ester resin, followed by vacuum stirring to obtain a resin composition.

  The obtained resin composition is poured into a casting mold that has been previously treated with a release agent, cured by heating at 90 ° C. for 2 hours, and then completely cured by annealing at 60 ° C. for 2 hours after demolding. I let you. The surface of the obtained cured product was polished by sand blasting with # 800 to obtain an artificial marble base material.

  Zinc oxide (NANOFINE 50A / manufactured by Sakai Chemical Co., Ltd.) MTMS dispersion as an ultraviolet light blocking agent is added to 100 parts by mass of silicone resin (KR-282 / Shin-Etsu Chemical Co., Ltd.) so that the amount of zinc oxide is 30 parts by mass. The mixture was added and stirred for a predetermined time. Thereafter, 3 parts by mass of a silane coupling agent (KBM-603 / Shin-Etsu Chemical Co., Ltd.) as a curing catalyst is added with respect to 100 parts by mass of the silicone resin, and further stirred for a predetermined time to obtain a coating resin composition. Obtained.

Subsequently, the artificial marble base material was obtained by spray-coating the obtained coating resin composition on the artificial marble base material so as to have a film thickness of 5 μm and curing at 120 ° C. for 20 minutes.
<Example 2>
An artificial marble substrate was obtained in the same manner as in Example 1.

  In the coating resin composition of Example 1, a coating resin composition was obtained in the same manner as in Example 1 except that zinc oxide was added to 20 parts by mass with respect to 100 parts by mass of the silicone resin.

The artificial marble deck base material was obtained by the same method as Example 1 using the obtained coating resin composition.
<Comparative Example 1>
An artificial marble substrate was obtained in the same manner as in Example 1.

  3 parts by mass of a silane coupling agent (KBM-603 / Shin-Etsu Chemical Co., Ltd.) is added as a curing catalyst to 100 parts by mass of silicone resin (KR-282 / Shin-Etsu Chemical Co., Ltd.), and Stirring was performed for a predetermined time to obtain a coating resin composition.

The artificial marble deck base material was obtained by the same method as Example 1 using the obtained coating resin composition.
<Comparative example 2>
1 part by weight of a curing agent (Perocta O / manufactured by Nippon Oil & Fats Co., Ltd.) and 100 parts by weight of a vinyl ester resin (Neopol 8101 / manufactured by Nippon Iupika Co., Ltd.), UV absorber (JF-80 / Johoku Chemical Co., Ltd.) ) 1 part by mass was added and stirred for a predetermined time. Thereafter, 200 parts by mass of aluminum hydroxide (CW-310SH, manufactured by Sumitomo Chemical Co., Ltd.) as an inorganic filler was added to 100 parts by mass of the vinyl ester resin, followed by vacuum stirring to obtain a resin composition.

The obtained resin composition is poured into a casting mold that has been previously treated with a release agent, cured by heating at 90 ° C. for 2 hours, and then completely cured by annealing at 60 ° C. for 2 hours after demolding. I let you. The surface of the resulting cured product was sandblasted with # 800 to obtain an artificial marble deck substrate.
<Performance test>
About the artificial marble deck base material obtained by Example 1-2 and Comparative Example 1-2, the weather resistance and the adhesiveness of the coating film were evaluated.
<Evaluation of weather resistance>
The weather resistance was evaluated using an accelerated weather resistance tester (eye super UV tester W151 / Iwasaki Electric). The test was performed at an ultraviolet irradiation intensity of 100 mw / cm ² for 50 hours. Judgment criteria are as follows.

○: ΔE = 3 or less, no coating film peeling Δ: ΔE = 3 or more and less than 10, no coating film peeling ×: ΔE = 10 or more, or coating film peeling In this example and comparative example, “Δ” There was no artificial marble deck substrate to evaluate.
<Evaluation of adhesion>
Before and after evaluation of weather resistance by an accelerated weather resistance tester, a cross-cut adhesion test (25 squares) was performed based on JIS K5600 to evaluate the adhesion of the coating film.
Judgment criteria are as follows.

○: No 25/25 coating film peeling △: No more than 20/25 coating film peeling ×: No peeling less than 20/25 In this example and the comparative example, the artificial marble deck base material that is evaluated as “Δ” is There wasn't.

  The results are shown in Table 1.

  As shown in the results of Table 1, since the artificial marble deck base material obtained in Example 1-2 has a layer (coating film) of a silicone resin containing an ultraviolet cut agent on the surface, comparison is made. It was confirmed that the weather resistance was superior to the artificial marble deck base material obtained in Example 1-2. Further, the adhesion of the coating film of the artificial marble deck substrate obtained in Example 1-2 is the artificial marble deck base obtained in Comparative Example 1 after the evaluation of the weather resistance by the accelerated weather resistance tester. It was also confirmed that it was superior to the material. From this, it was confirmed that the artificial marble deck base material obtained in Example 1-2 can be used for a long time even outdoors.

  On the other hand, the artificial marble deck base material obtained in Comparative Example 1-2 is inferior in weather resistance since a layer of a silicone resin containing an ultraviolet blocking agent is not formed on the surface.

1 Deck Material 2 Base Material 3 Silicone Resin Layer Containing UV Cut Agent

Claims (3)

  A deck material, characterized in that a layer of a silicone resin containing a UV-cutting agent is formed on the surface of a plate-like substrate made of artificial marble.   The deck material according to claim 1, wherein the artificial marble is a vinyl ester type artificial marble. The deck material according to claim 1, further comprising a foot portion for fixing the base material.

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