JP3040737B2 - Manufacturing method of foam plastic plate - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing a synthetic resin composite plate which is mainly made of a thermosetting resin foam, has a reinforcing material embedded in the foam layer, and is light and excellent in strength. For example, the present invention provides a synthetic resin composite plate that can be used as a groove cover of a road gutter, a cover plate of various liquid tanks, and an inner wall material, an outer wall material, a roof material, a floor material, a decorative board, a heat insulating material, and the like of a building.

[0002]

2. Description of the Related Art Conventionally, building materials such as inner wall materials, outer wall materials, roofing materials, flooring materials, decorative boards, heat insulating materials, and the like include stone materials, artificial stones, clay products (eg, tiles), gypsum boards, decorative veneers, and the like. Used. However, stones, artificial stones, and clay products are heavy in weight, increasing the transportation cost, requiring the columns and the like that support them to be strengthened, and have problems such as a hard surface. Further, gypsum board and decorative veneer cannot be used in places where water is applied, and have problems such as short service life. Also, rigid urethane and PVC foam are known as core materials, but these have inferior heat resistance, cause distortion and deterioration at high temperatures, and styrene foam lacks chemical resistance, so that painting and bonding are difficult. could not.

On the other hand, a synthetic resin composite plate in which a foamed plastic plate is used as a core material and an outer surface layer of a fiber reinforced plastic is laminated on both front and back surfaces thereof is lightweight and has excellent strength.
It is used in various fields. However, conventionally,
Using an unsaturated polyester resin and glass fiber, a pair of upper and lower gutters are formed in advance, and the pair of gutters are stacked together to form a flat cylindrical bag. An opening at one end is formed inside the bag. Since the mixture of unsaturated polyester resin and compressed gas was injected from the part and was cured, the above resin generated heat during the curing, and the degree of heat radiation was different between the center and the mouth of the bag, resulting in air bubbles The performance of the product becomes uneven due to variations in the size and cracks, and this unevenness of performance is especially large when a thin step is provided, such as a parting plate. In addition, the shape of the bag made of fiber reinforced plastic, that is, the shape of the composite plate is limited.

[0004] A foamed plastic plate made of a thermosetting resin foam such as an unsaturated polyester resin, which is lighter, softer, and more excellent in strength than conventional stone materials, and has water resistance, heat resistance and chemical resistance. As a method of obtaining, filling the uncured foamed plastic obtained by mixing the thermosetting resin and the compressed gas into the box-shaped upper mold and lower mold, respectively,
Then, it has been proposed to close the upper mold and the lower mold and cure the foamed plastic at room temperature (see Japanese Patent Application No. 9-127934).

Further, in the method for producing a synthetic resin composite plate in which the above-mentioned thermosetting resin foam is used as a core material and this core material is covered with an outer surface layer of fiber reinforced plastic, the outer shape of the composite resin plate is rectangular, circular or the like. It can be set arbitrarily, and even when there is a small thickness part such as a step part for joint breakage, bubbles are formed to a uniform size, cracks do not occur in the core material, and performance is uniform As a method of manufacturing a resin composite plate, an upper box-shaped portion constituting the upper half of the outer layer and a lower box-shaped portion constituting the lower half are separately molded with the above fiber-reinforced plastic, and the upper and lower portions are formed. Fill the box-shaped part with foamed plastic made by mixing thermosetting resin and compressed gas, respectively,
Thereafter, it has been proposed that the upper and lower box-shaped portions are overlapped in a mold shape and the foamed plastic is cured (see Japanese Patent Application No. 9-114350).

However, in order to increase the strength of the foamed plastic plate and the synthetic resin composite plate of the prior application, it is necessary to increase the thickness. However, if the thickness is increased, the foamed plastic is hardened. There is a problem in that the temperature rises rapidly until the temperature rises, causing shrinkage.

[0007]

SUMMARY OF THE INVENTION The present invention relates to a plate material comprising an outer surface layer made of a thermosetting resin foam such as the above-mentioned unsaturated polyester resin and made of fiber-reinforced plastic and a plate material having no outer surface layer. By embedding a reinforcing material in the foamed layer, the strength is improved without increasing the thickness.

[0008]

The first means is a method suitable for producing a relatively thick foamed plastic plate having no outer layer made of fiber reinforced plastic. Fill the upper and lower molds with an uncured foamed plastic obtained by mixing a thermosetting resin and a compressed gas, and then close the upper and lower molds and remove the foamed plastics at room temperature. In the method for producing a foamed plastic plate to be cured, a reinforcing material for reinforcing the foamed plastic plate is disposed on at least one of the upper mold and the lower mold before or after filling with the uncured foamed plastic.

In the first means, the thermosetting resin used as a raw material of the foamed plastic plate may be a conventional thermosetting resin such as an unsaturated polyester resin, a vinyl ester resin (epoxy acrylate resin), an epoxy resin, a phenol resin, a furan resin or the like. It is a curable resin and is appropriately selected depending on the application. In particular, unsaturated polyester resins and vinyl ester resins are preferable because they can be cured at room temperature and are excellent in strength, heat resistance, water resistance, chemical resistance and the like. The unsaturated polyester resin may be any of an isophthalic acid type, a terephthalic acid type, a bisphenol type, a heptic acid type and the like, and the vinyl ester resin may be any of a bisphenol type and a novolak type.

In the first means, a box-shaped upper mold and a lower mold are used. The upper mold is formed in a box shape corresponding to one side in the thickness direction of a foamed plastic plate as a product, and the lower mold is formed in a box shape corresponding to the other side in the thickness direction of the foamed plastic plate. That is, when both the upper mold and the lower mold are combined, the inner space (cavity) is formed so as to have the same shape as the foamed plastic plate as a product. In this case, the planar shape of the cavity in the upper die and the lower die may be any of a square, a rectangle, a circle, a pentagon and the like, and an arbitrary shape is selected according to the purpose. In addition, the upper mold and the lower mold do not necessarily have to have the same planar shape and depth, and may differ depending on the purpose.
Also, any irregularities can be provided on the bottom surface of the cavity.

The above-mentioned upper mold and lower mold are filled with a foamed plastic which is a mixture of the thermosetting resin and the compressed gas by spraying or pouring in an uncured state. The above mixture can be made by a known method, for example, a mechanical compounding foaming system (MBF system) of Venus Gasmer. This MBF system is a method in which a thermosetting resin is uniformly mixed with a compressed gas to form a foam, then mixed with a curing agent to form a thermosetting resin foam by spraying or casting, and cured at room temperature. is there.

As the compressed gas, any non-flammable gas such as carbon dioxide, nitrogen, argon and air can be used. Then, the structure of the cells and the specific gravity of the foamed plastic plate are adjusted by the type of gas and thermosetting resin used, the pressure, the amount of the additive, and the like. For example, when an unsaturated polyester resin or a vinyl ester resin is used, the bubbles are large and the specific gravity is 0.25 to 0.25.
Carbon dioxide gas is preferred for reducing to about 0.40, while nitrogen gas is preferred for reducing bubbles and increasing specific gravity to about 0.40 to 0.45.

Before the thermosetting resin is mixed with the compressed gas, the thermosetting resin is heated to a plasticizing melting temperature lower than the curing start temperature to reduce the viscosity, and then the compression is performed. Mixing with a gas is preferred, in which case mixing with the compressed gas is facilitated and the resulting foamed plastic foam has a uniform size. For example, since the unsaturated polyester resin starts curing at a high temperature without adding a curing agent, it is preferable to lower the viscosity by heating to a plasticization melting temperature 30 to 50 ° C. lower than the curing start temperature. . In addition, at the time of this heating, as described in claim 6, it is preferable to add a curing accelerator for assisting the curing of the thermosetting resin after foaming, a foam stabilizer for preventing bubbles from disappearing, and the like. Mixing with the compressed gas becomes easier, and when the upper and lower molds are cooled by contact with the atmosphere when they are filled, the viscosity increases and bubbles are less likely to disappear.

According to the present invention, before or after filling the above-mentioned foamed plastic into the upper mold and the lower mold, at least one of the upper mold and the lower mold is provided with a reinforcing material for reinforcing a foamed plastic plate to be a product. You. This stiffener can be made of fiber reinforced plastic or metal. Fiber reinforced plastics are preferred in that they have good adhesion to foamed plastics and are light, and metallic ones are preferred in that they have excellent strength. The shape can be any shape such as a flat plate, a T-shaped cross-section, an I-shaped cross-section, an H-shaped cross-section, a C-shaped cross-section, and an L-shaped cross-section. Alternatively, the pipe may have a square or circular cross section. In this case, it may be either a foamed plastic inside or not. In addition, the above-mentioned reinforcing material can form irregularities on the surface in order to improve the adhesiveness with the foamed plastic, and particularly in the case of a reinforcing material having a flat, T-shaped or I-shaped cross section, penetrates a vertical plane. Many holes can be made to connect the foam plastics on both sides.

It is preferable that the length of the reinforcing member is as long as possible within a range in which the reinforcing member and the lower die can be arranged in the length direction or the width direction. Further, it is preferable that the height be as high as possible in a range where the upper mold and the lower mold are straddled over the two when the upper mold and the lower mold are overlapped in a mold form. However, a reinforcing material that spans the upper and lower molds is placed on either the upper or lower mold,
The protruding portion may be inserted into the other when the upper mold and the lower mold overlap. In addition, the reinforcing material of half the height that spans the upper and lower molds is individually arranged in the upper and lower molds,
The upper die and the lower die may be overlapped by stacking the upper die and the lower die in a combined die shape.

When the foamed plastic is filled in the upper mold and the lower mold, the upper mold and the lower mold are put together with the foamed plastic inside, and the foamed plastic is left standing at room temperature in this state. The plastic is cured. With this curing, the foamed plastic in the upper mold and the foamed plastic in the lower mold are integrated with each other by bonding, and at the same time, the foamed plastic and the reinforcing material are bonded. At this time, the bubbles disappear from the portion in contact with the upper mold and the lower mold of the foamed plastic, and a dense skin layer is formed. Therefore, it is a foamed plastic plate in which the cavities of the upper mold and the lower mold are combined, and has a dense skin layer on the surface, the bubbles inside the skin layer are uniform, and the foamed plastic sheet is reinforced with a reinforcing material. A plate is obtained. In addition, by adjusting the compounding amount of a curing agent or a curing accelerator so that curing starts immediately after filling of the foamed plastic, the foam is suppressed from being broken by the weight of the foamed plastic itself, and the thickness of the skin layer is reduced. be able to.

The first means is to mix a thermosetting resin and a compressed gas (foamed plastic) in both the upper mold and the lower mold.
Is suitable for producing a foamed plastic plate having a relatively large thickness. In the first means, the upper mold and the lower mold can have different depths. Further, by making the outer shapes (contours of the cavities) of the upper die and the lower die different and projecting one edge from the other edge, a foamed plastic plate having a step at the edge can be manufactured. In this case, the protruding side of the foamed plastic surface is preferably covered with a flat mold surface or lid plate following the other edge.

Further, the upper mold and the lower mold are formed into the same square or rectangle and at the same depth, and the upper mold and the lower mold are filled with the above-mentioned foamed plastic, and the upper mold and the lower mold are combined. By shifting in the length or width direction,
A foamed plastic plate provided with a step for the joint is obtained. Also in this case, the protruding side of the foamed plastic surface is preferably covered with the other mold surface or the cover plate.

The second means is a method suitable for producing a relatively thick foamed plastic plate having an outer surface layer made of fiber reinforced plastic. A fiber-reinforced plastic is laminated in an uncured state in advance along the inner surfaces of the upper and lower molds to be filled with foamed plastic, cured to form a box-shaped outer layer, and then the reinforcing material is placed and the uncured foamed plastic is formed. Then, the foamed plastic is cured to produce a foamed plastic plate having a box-shaped outer surface layer on the outer surface.

In the second means, the thermosetting resin for the fiber-reinforced plastic in the box-shaped outer layer is the same as that for the foamed plastic described above, and in particular, the unsaturated polyester resin and the vinyl ester resin are made of glass. It is preferable because it has good impregnating properties with respect to reinforcing fibers such as fibers, can be cured at room temperature, and has excellent water resistance and chemical resistance. In particular, it is preferable to use the same kind of foamed plastic as the core material, in terms of adhesiveness.

As the reinforcing fiber, any fiber such as glass fiber, carbon fiber, synthetic fiber such as nylon and polyester, and cotton fiber can be used, and it is selected according to the application. Fibers and carbon fibers are preferred. These fibers can be used in the form of rovings, chopped strands, mats, cloths, and the like, like ordinary fiber-reinforced plastics. To form the box-shaped outer layer, any method such as a hand lay-up method, a spray-up method, a prepreg method, a matched die method, or a premix method can be adopted, but the spray-up method is particularly preferable. .

Then, when the upper and lower two upper and lower box-shaped outer layers are formed and cured, the upper and lower box-shaped outer layers are respectively connected to the upper and lower molds. Other than assuming that, in the same manner as the first means described above, a reinforcing material is placed inside and filled with uncured foamed plastic, or a reinforcing material is placed after filling with uncured foamed plastic, Thereafter, the upper mold and the lower mold are closed and the above-mentioned foamed plastic is cured at room temperature to produce a foamed plastic plate covered with an outer layer of fiber reinforced plastic and reinforced with a reinforcing material.

The third means is a method suitable for manufacturing a foamed plastic plate having a relatively small thickness without an outer surface layer made of fiber reinforced plastic. Fill the uncured foamed plastic obtained by mixing the curable resin and the compressed gas, and then cover the surface of the foamed plastic filled in the lower mold with a lid plate-shaped upper mold to cover the foamed plastic. In the method for producing a foamed plastic plate cured at room temperature, a reinforcing material for reinforcing the foamed plastic plate is disposed on the lower mold before or after filling with the uncured foamed plastic.

In the third means, a lower die similar to the lower die of the first means and a lid plate-shaped upper die covering the opening thereof are used. That is, a box-shaped lower mold having a shallow bottom that can accommodate the above-mentioned foamed plastic plate is prepared. In this case, the planar shape of the cavity may be any of a square, a rectangle, a circle, a pentagon, and the like, and an arbitrary shape is selected according to the purpose. Also, any irregularities can be provided on the bottom surface of the cavity.

A cover plate which fills the above-mentioned foamed plastic after disposing the same reinforcing material inside the lower mold, or arranges a reinforcing material after filling this foamed plastic, and thereafter covers the foamed plastic. When the foamed plastic is cured by stacking the upper mold, the foamed plastic disappears in the portion in contact with the inner surface of the lower mold and the lower surface of the upper mold, and a dense skin layer is formed. Thus, a foamed plastic plate having uniform air bubbles and embedded with a reinforcing material is obtained.

The fourth means is a method suitable for producing a foamed plastic plate having a relatively small thickness having an outer layer made of fiber reinforced plastic. While the fiber-reinforced plastic is laminated in an uncured state in advance along the inner surface of the lower mold to be filled with the cured foamed plastic and cured to form a box-shaped outer layer, the fiber-reinforced plastic forms the box-shaped outer layer. Form a lid plate-shaped outer layer covering the upper opening, and then arrange the reinforcing material and fill the uncured foamed plastic, and place the lid plate-shaped cover on the uncured foamed plastic filled in the box-shaped outer layer. An outer surface layer and an upper mold are sequentially stacked, and then the foamed plastic is cured to produce a foamed plastic plate having a box-shaped outer surface layer on the outer surface.

In the fourth means, a box-shaped outer surface layer is formed of fiber-reinforced plastic on the inner surface of the lower mold in the same manner as for the lower mold of the second means, and is cured. On the other hand, a cover plate-like outer surface layer covering the upper opening of the box-shaped outer surface layer is molded and cured on the lower surface of the upper plate-shaped upper mold or on an arbitrary flat plate using the same fiber-reinforced plastic as described above. And after these curing, the reinforcing material is placed in the box-shaped outer surface layer inside the lower mold and filled with uncured foamed plastic, or the reinforcing material is placed after filling the uncured foamed plastic, Thereafter, the above-mentioned foamed plastic is cured at room temperature by stacking the lid plate-like outer surface layers, whereby a foamed plastic plate covered with the outer layer of fiber reinforced plastic and reinforced with a reinforcing material is produced.

[0028]

BEST MODE FOR CARRYING OUT THE INVENTION

Embodiment 1 In FIG. 1, 11 is an upper mold, 12 is a lower mold, each has a cavity having the same plane shape as the target foamed plastic plate 10, and has a depth of half the thickness of the foamed plastic plate 10, It is formed in a box shape that is long in the direction perpendicular to the paper,
Flanges 11a and 12a project from four sides of the upper surface opening. Inside each of the upper mold 11 and the lower mold 12, a plurality of flat reinforcing members 13 long in a direction perpendicular to the paper surface formed of a fiber-reinforced plastic made of glass fiber and unsaturated polyester resin are provided with a width. They are arranged parallel to each other with a desired interval with their directions pointing up and down. The upper mold 11 is formed to be reversible.

On the other hand, a predetermined amount of an unsaturated polyester resin, an appropriate amount of a foam stabilizer and a proper amount of a curing accelerator are put into a resin tank (not shown) installed in a room having an outside air temperature of 3 to 30 ° C., and the mixture is stirred. Then, while stirring, the resin temperature is raised to a plasticizing melting temperature of 30 to 50 ° C. lower than the curing start temperature. Thereafter, the unsaturated polyester resin having the reduced viscosity is supplied to a mechanical compounding and foaming apparatus manufactured by Venus Gasmer Co., Ltd., and the temperature is maintained at the above-mentioned plasticization melting temperature by an in-line heater, and the pressure is set to 1000 to 5000 kp.
a. Mix with a non-flammable gas (eg, nitrogen gas).

The mixture of the obtained unsaturated polyester resin and the compressed gas, that is, the foamed plastic 14, is charged into the upper mold 11 and the lower mold 12 while being mixed with a curing agent using a spray gun. Subsequently, as shown by a chain line in the middle of FIG. 1, the upper mold 11 is inverted and overlapped on the lower mold 12, whereby the reinforcing members 13 in the upper mold 11 and the lower mold 12 and the foamed plastics 14 are overlapped with each other. Then, the foamed plastic 14 is integrally adhered as an adhesive, left standing at room temperature to cure the foamed plastic 14 at room temperature, and after the curing is completed, the upper mold 11 is opened, and the foamed layer 14a made of the cured foamed plastic 14 is opened. Dense skin layer 14b on the surface of
And take out a rectangular foamed plastic plate 10 in which a plurality of reinforcing members 13 are embedded.

Embodiment 2 As shown in FIG. 2, the left flange 11b of the upper die 11 is formed longer than the other flange 11a, and the right flange 12b of the lower die 12 is formed longer than the other flange 12a. A plurality of reinforcing members 13 are set in the upper mold 11 and the lower mold 12 in the same manner as in the first embodiment, filled with foamed plastic 14, and the upper mold 11 is inverted to form the lower mold 12 as shown by a chain line. Then, the foamed plastic 14 is hardened at room temperature, and then the upper mold 11 is opened to have a dense skin layer 14b on the surface of the foamed layer 14a, and a plurality of reinforcing materials 13 are buried therein. A foamed plastic plate 10A having a rectangular shape that is long in the vertical direction and provided with a step portion 10a for a joint on the left and right sides is obtained. When a plurality of the foamed plastic plates 10A are arranged in the horizontal direction in FIG.

Embodiment 3 As shown in FIG. 3, an upper mold 11 and a lower mold 12 are formed in the same manner as in the embodiment 2 and the embodiment 1, respectively.
A plurality of reinforcing materials 13 are set in the same manner as described above in the first mold 1 and the lower mold 12, filled with a foamed plastic 14, the upper mold 11 is turned over and stacked on the lower mold 12, and the foamed plastic 14 is cured at room temperature. After that, the upper mold 11 is opened to have a dense skin layer 14b on the surface of the foam layer 14a, and a plurality of reinforcing members 13 are buried therein. A foamed plastic plate 10B having a connecting step 10a is obtained. The foamed plastic plate 10B is the same as the foamed plastic plate 10A of the second embodiment.
Can be arranged at both ends to form a joint.

Embodiment 4 As shown in FIG. 4, the same box-shaped lower mold 1 as in Embodiment 1 is used.
2, the reinforcing material 13 is set in the same manner as in the first embodiment, and the foamed plastic 14 is filled. On top of this, a flat plate-shaped upper die 16 is stacked on the lid plate instead of the box-shaped upper die 11 of the first embodiment. Thereafter, the foamed plastic 14 is cured at normal temperature, the flat upper mold 16 is opened, and the foamed plastic plate 1 has the same structure as the foamed plastic plate 10 of FIG.
Obtain about half of the foamed plastic plate.

Embodiment 5 As the upper mold 11, one having left and right flanges 11 a of Embodiment 1 formed as long as the left flange 11 b of Embodiment 2 is used, and as the lower mold 12, the same one as in Embodiment 1 is used. In the following, as in the first embodiment, the reinforcing material 13 is set, the foamed plastic 14 is filled, and the upper mold 11 is connected to the lower mold 1.
2, the foamed plastic 14 is cured at room temperature,
Thereafter, the upper mold 11 is opened, and as shown in FIG. 5, a rectangular layer having a dense skin layer 14b on the surface of the foamed layer 14a and a plurality of reinforcing members 13 embedded therein, and being long in a direction perpendicular to the paper surface. Thus, a foamed plastic plate 10C having symmetrical steps 10a on both left and right sides is obtained. When a large number of the foamed plastic plates 10C are arranged in the horizontal direction, by alternately inverting the top and bottom of the foamed plastic plates 10C, it is possible to perform a spliced joint. 10B is placed.

Embodiment 6 As shown in FIG. 6, the same upper mold 11 and lower mold 12 as in Embodiment 1 are each coated with a fiber-reinforced plastic comprising glass fiber and unsaturated polyester resin to a desired thickness by a spray-up method. The box-shaped outer layer 17 is formed along the inner surfaces of the upper mold 11 and the lower mold 12 by laminating and curing at room temperature. Hereinafter, in the same manner as in the first embodiment, the upper mold 11
A plurality of reinforcing members 13 made of fiber reinforced plastic are set in the lower mold 12 and
Is filled while mixing with a curing agent, and as shown by a dashed line 11, the upper mold 11 is turned over and overlapped with the lower mold 12, and the outer surface layers 17 in the upper mold 11 and the lower mold 12, the reinforcing materials 13 and the foam are formed. The plastics 14 are integrally adhered to each other using the foamed plastic 14 as an adhesive, and left at room temperature to cure the foamed plastic 14 at room temperature. After the curing is completed, the upper mold 11 is opened and the cured foamed plastic 14 is opened.
The entire surface of the foam layer 14a made of fiber reinforced plastic 1
7 to obtain a rectangular foamed plastic plate 20 in which a plurality of reinforcing members 13 are embedded. Since the foamed plastic plate 20 has the outer surface layer 17 of fiber reinforced plastic, the strength is further improved as compared with the first embodiment.
In addition, by using the box-shaped lower mold 12 and the flat upper mold 16 of Embodiment 4 (FIG. 4) and forming an outer layer of fiber-reinforced plastic on the inner surface, the outer layer and the reinforcing material are provided. A foamed plastic plate having a thickness of about half is obtained.

Embodiment 7 In FIG. 7, the same upper mold 11 and lower mold 12 as those used in the second embodiment are used as the upper mold 11 and the lower mold 12.
An outer surface layer 17 of the same fiber-reinforced plastic as that of the sixth embodiment is formed along the inner surface of the lower mold 12. However, the upper and lower dies 12 on the left side flange 11b of the upper dies 11
On the right side flange 12b of the outer layer 1
The tongue piece 17a following 7 is integrally formed. Hereinafter, the reinforcing material 13 is set in the same manner as described above, the foamed plastic 14 is filled, and the upper mold 11 is overlapped with the lower mold 12. The surface of the foamed plastic 14 in the upper mold 11 is pressed by the tongue piece 17a of the lower mold 12. After a while
The foamed plastic 14 is cured, the upper mold 11 is opened, and the entire surface of the foamed layer 14a made of the cured foamed plastic 14 is covered with the outer surface layer 17 of the fiber-reinforced plastic, and a plurality of reinforcing members 13 are embedded and A rectangular shape that is long in the vertical direction, and has a stepped portion 20a for a joint on the left and right sides.
To obtain a foamed plastic plate 20A. This foamed plastic plate 20 </ b> A can be used for split joining as in the second embodiment.

Embodiment 8 As shown in FIG. 8, an outer surface layer 17 with a tongue piece 17a is formed by using the same upper mold 11 as in Embodiment 7, and the same as Embodiment 6 as lower mold 12. Outer layer 17
Is molded. Hereinafter, the reinforcing material 13 is set as described above,
The foamed plastic 14 is filled, and the upper mold 11 is placed on the lower mold 12. At this time, the surface of the foamed plastic 14 in the lower mold 12 is pressed by the tongue piece 17 a on the upper mold 11 side, and then the foamed plastic 14 is cured. The upper mold 11 is opened, and the entire surface of the foamed layer 14a made of the cured foamed plastic 14 is covered with an outer surface layer 17 of fiber reinforced plastic, and a plurality of reinforcing members 13 are embedded. Then, a foamed plastic plate 20B having a stepped portion 20a for a joint on the left side is obtained. This foamed plastic plate 20B is the same as the foamed plastic plate 20A of the seventh embodiment.
Can be arranged at both ends thereof.

In the first to eighth embodiments, the reinforcing member 1
The setting of 3 may be performed after filling the foamed plastic 14. Further, the reinforcing material 13 used in the first to eighth embodiments includes:
It is a flat plate having a width equal to the depth of the upper die 11 or the lower die 12, but its height is set to be greater than the depth of one of the upper die 11 and the lower die 12. 12, and a portion where the reinforcing material 13 protrudes from one side may be pierced into the other foamed plastic 14 when the upper mold 11 and the lower mold 12 filled with the foamed plastic 14 are overlapped. .

The foamed plastic plates 10, 10A,
Depending on the shape of 10B, 10C, 20, 20A, 20B, etc., as shown in FIG. 9, the reinforcing members 13 intersect at right angles, one of which extends in the length direction of the upper mold and the lower mold, and the other in the width direction. Can be used for Further, in order to improve the adhesive strength between the reinforcing material 13 and the foamed plastic 14 (foam layer 14a), irregularities are provided on both surfaces of the reinforcing material 13 (see 13a in FIG. 10), and a large number of holes are formed in the reinforcing material 13. can do. Further, as shown by 13b, 13c and 13d in FIG. 10, the cross-sectional shape may be T-shaped, C-shaped, L-shaped, H-shaped or any other shape.

[0040]

【Example】

Example 1 An upper mold 11 and a lower mold 12 of FIG.
Using a terephthalic acid-based unsaturated polyester resin (trade name "Yupika 6400" manufactured by Nippon Yupika Co., Ltd.), FIG.
Foamed plastic plate 10 shown in the lower section (total thickness 80m)
m, total width 600mm, total length 3000mm, dense skin layer 14
b thickness 0.1 mm). First, the reinforcing material 13
A flat plate having a thickness of 5 mm, a width of 40 mm, and a length of 2990 mm was formed from a fiber reinforced plastic comprising glass fibers and the above-mentioned unsaturated polyester resin, and five flat plates were arranged on the upper mold 11 and the lower mold 12.

On the other hand, at room temperature, 100 parts by weight of the above-mentioned terephthalic acid-based unsaturated polyester resin was placed in a resin tank, and a foam stabilizer (trade name "UPICA S" manufactured by Nippon Yupica KK)
(TV) 1 part by weight and 0.25 parts by weight of 12% cobalt octylate (curing accelerator) were added, and the resin tank was heated while slowly stirring to raise the temperature of the resin to 50 ° C. Next, the above unsaturated polyester resin is supplied to a mechanical compounding and foaming apparatus manufactured by Venus Gasmer, and is mixed with nitrogen gas at a pressure of 3500 kpa while maintaining the resin temperature at 45 ° C. with an in-line heater in the apparatus. Fine bubbles were uniformly generated in the saturated polyester resin to obtain a foamed plastic 14.

Next, the above-mentioned foamed plastic 14 was sprayed and filled inside the upper mold 11 and the lower mold 12 by a spray-up method. However, a hardener (trade name “Percure HB”, manufactured by NOF Corporation) was added to the above-mentioned foamed plastic at 1 part by weight per 100 parts by weight of the foamed resin at the inlet side of the spray gun while spraying was performed. Then, the upper mold 11 filled with the foamed plastic 14 was inverted and overlaid on the lower mold 12, and both foamed plastics 14 were united and cured at room temperature.

The resulting foamed plastic plate 10 weighed 70 kg. The foamed plastic plate 10
Is supported by two fulcrums (distance between fulcrums: 2500 mm) and an evenly distributed load (360 kg / m ² ) is applied, the deflection at the center is less than 20 mm, and the original shape is restored immediately when the load is removed. did. On the other hand, the foamed plastic plate of Comparative Example 1 manufactured in the same manner as described above except that the reinforcing material 13 was omitted had a weight of 60 kg and a deflection of 40 mm.

Example 2 An outer layer 17 having a thickness of 1.8 mm was previously formed on the inner surface of the upper mold 11 and the lower mold 12 used in Example 1 with the fiber reinforced plastic comprising the above glass fiber and unsaturated polyester resin. Molded. Thereafter, as in the first embodiment, a reinforcing material (a flat plate having a thickness of 5 mm, a width of 35 mm, and a length of 2990 mm) 1
3 are arranged 5 by 5 and filled with foamed plastic 14,
The upper mold 11 and the lower mold 12 are stacked, and
Was cured at room temperature. The weight of the obtained foamed plastic plate 20 with the outer surface layer 17 was 78 kg, and the same bending test as in Example 1 was performed. As a result, the center bending was 20 mm. The weight of Comparative Example 2 obtained in the same manner as in Example 2 except that the reinforcing material 13 was omitted was 76 kg, and the flexure was 30 mm.

[0045]

According to the first aspect of the present invention, there is provided a foamed plastic plate comprising a dense skin layer and a foamed layer inside the foamed layer, wherein a reinforcing material is buried in the foamed layer and used for a conventional stone material or the like. Lighter, softer, and stronger than water, heat and chemical resistant, and can be used in place of conventional stone, artificial stone, clay products, gypsum board, decorative veneer and foam resin products A plate material is obtained. In addition, it is possible to manufacture a foamed plastic plate of not only a rectangular shape but also a circular shape or any other shape, and at that time, the shape and performance become uniform. Further, it is possible to easily manufacture a plate material in which a portion having a small thickness exists, such as a step portion for a joint, in the foamed plastic plate.

According to a second aspect of the present invention, the foamed plastic plate according to the first aspect is covered with an outer layer of a fiber-reinforced plastic, and the outer surface is more excellent in strength than the foamed plastic plate. A foamed plastic plate with layers is obtained.

According to the third aspect of the present invention, a foamed plastic plate having the same structure as the foamed plastic plate of the first aspect and having a small thickness and a predetermined shape can be relatively easily manufactured. According to the fourth aspect of the present invention, it is possible to relatively easily manufacture a foamed plastic plate having a predetermined shape and a small thickness with the same structure as the foamed plastic plate with an outer layer according to the second aspect.

Further, in the invention according to claim 5, the viscosity is reduced by preheating the thermosetting resin, so that the mixing with the compressed gas becomes easy. In the invention according to claim 6, since the curing accelerator and the foam stabilizer are added at the time of the preheating, the mixing with the compressed gas is further facilitated, and the bubbles are hardly eliminated, and the bubbles of the foamed plastic are reduced. Are formed more uniformly.

[Brief description of the drawings]

FIG. 1 is a cross-sectional view illustrating a manufacturing method according to a first embodiment.

FIG. 2 is a cross-sectional view illustrating a manufacturing method according to a second embodiment.

FIG. 3 is a cross-sectional view illustrating a manufacturing method according to a third embodiment.

FIG. 4 is a cross-sectional view illustrating a manufacturing method according to a fourth embodiment.

FIG. 5 is a cross-sectional view illustrating a manufacturing method according to a fifth embodiment.

FIG. 6 is a cross-sectional view illustrating a manufacturing method according to a sixth embodiment.

FIG. 7 is a cross-sectional view illustrating a manufacturing method according to a seventh embodiment.

FIG. 8 is a cross-sectional view illustrating a manufacturing method according to an eighth embodiment.

FIG. 9 is a perspective view showing a modification of the reinforcing member.

FIG. 10 is a sectional view showing another modification of the reinforcing member.

[Explanation of symbols]

10, 10A, 10B, 10C, 20A, 20B: Foamed plastic plate 10a, 20a: Step for joint break 11: Upper die 12: Lower die 11a, 11b, 12a, 12b: Flange 13, 13a, 13b, 13c, 13d: Reinforcing material 14: Foam plastic 14a: Foam layer 14b: Skin layer 16: Flat upper mold 17: Outer surface layer 17a: Tongue piece

──────────────────────────────────────────────────続 き Continuation of the front page (51) Int.Cl. ⁷ Identification symbol FI B29K 105: 04 105: 08 105: 20 (56) References JP-A-4-216834 (JP, A) JP-A-54-129060 (JP, A) JP-A-10-286836 (JP, A) JP-A-10-296769 (JP, A) (58) Fields investigated (Int. Cl. ⁷ , DB name) B29C 39/02-39 / 12 B29C 39/22-39/40 B29C 44 / 00,67 / 20 C08J 9/30

Claims (6)

(57) [Claims] 1. A box-shaped upper mold and a lower mold are filled with uncured foamed plastic obtained by mixing a thermosetting resin and a compressed gas, respectively, and then the upper mold and the lower mold are closed. In a method for manufacturing a foamed plastic plate in which foamed plastic is cured at room temperature, a reinforcing material for reinforcing the foamed plastic plate in at least one of the upper mold and the lower mold before or after filling with the uncured foamed plastic. A method for manufacturing a foamed plastic plate, comprising disposing. 2. The method for producing a foamed plastic sheet according to claim 1, wherein a fiber-reinforced plastic is laminated in an uncured state in advance along inner surfaces of an upper mold and a lower mold to be filled with uncured foamed plastic. A method for producing a foamed plastic plate, which comprises curing to form a box-shaped outer surface layer, and then disposing a reinforcing material and filling the uncured foamed plastic, and then curing the foamed plastic. 3. A box-shaped lower mold is filled with an uncured foamed plastic obtained by mixing a thermosetting resin and a compressed gas. Then, the surface of the foamed plastic filled in the lower mold is covered with a cover plate. In a method for producing a foamed plastic plate, wherein the foamed plastic is cured at room temperature by coating with an upper mold,
A method for producing a foamed plastic plate, comprising: disposing a reinforcing material for reinforcing the foamed plastic plate in the lower mold before or after filling with the uncured foamed plastic. 4. The method of manufacturing a foamed plastic plate according to claim 3, wherein the fiber-reinforced plastic is laminated and cured in advance in an uncured state along the inner surface of the lower mold to be filled with the uncured foamed plastic. While forming the box-shaped outer layer, the cover-plate-shaped outer layer covering the upper opening of the box-shaped outer layer is formed with the above-mentioned fiber-reinforced plastic, and then the reinforcing material is placed and the uncured foamed plastic is filled. Perform, the lid plate-shaped outer layer and the upper mold in order on the uncured foamed plastic that is filled in the box-shaped outer layer,
Then, a method for producing a foamed plastic plate, in which the foamed plastic is cured. 5. The method for producing a foamed plastic plate according to claim 1, wherein the thermosetting resin is heated to a temperature lower than the curing start temperature before the thermosetting resin is mixed with the compressed gas. A process for producing foamed plastic plates that is heated to a low plasticizing melting temperature to reduce viscosity and then mixed with compressed gas. 6. A method for producing a foamed plastic sheet according to claim 5, wherein a curing accelerator and a foam stabilizer for making air bubbles hardly disappear when the thermosetting resin is heated to a plasticizing melting temperature. Manufacturing method of foamed plastic plate to be mixed.