JP3073707B2 - Manufacturing method of foam plastic plate - Google Patents
Manufacturing method of foam plastic plateInfo
- Publication number
- JP3073707B2 JP3073707B2 JP09127934A JP12793497A JP3073707B2 JP 3073707 B2 JP3073707 B2 JP 3073707B2 JP 09127934 A JP09127934 A JP 09127934A JP 12793497 A JP12793497 A JP 12793497A JP 3073707 B2 JP3073707 B2 JP 3073707B2
- Authority
- JP
- Japan
- Prior art keywords
- foamed plastic
- resin
- plastic plate
- mold
- thermosetting resin
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Fee Related
Links
Landscapes
- Casting Or Compression Moulding Of Plastics Or The Like (AREA)
Description
【０００１】[0001]
【発明の属する技術分野】この発明は、熱硬化性樹脂の
発泡体からなり、表面に緻密な表皮層を有し、軽く、か
つ強度に優れた発泡プラスチック板を製造する方法に関
し、例えば建物の内壁材、外壁材、屋根材、床材、化粧
板、断熱材等の建築資材として使用可能な発泡プラスチ
ック板を提供する。BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing a foamed plastic plate which is made of a thermosetting resin foam, has a dense skin layer on its surface, is lightweight and has excellent strength. Provided is a foamed plastic plate that can be used as a building material such as an inner wall material, an outer wall material, a roof material, a floor material, a decorative board, and a heat insulating material.
【０００２】[0002]
【従来の技術】従来、建築資材、例えば内壁材、外壁
材、屋根材、床材、化粧板、断熱材等として石材、人造
石、粘土製品（例えば、タイル）、石膏ボード、化粧ベ
ニヤ等が用いられている。しかし、石材や人造石、粘土
製品は重量が大きいために輸送コストが嵩み、これらを
支える柱等を強くする必要が生じ、更に表面が固い等の
問題があった。また、石膏ボードや化粧ベニヤは、水の
かかる所に使用できず、耐用年数が短い等の問題があっ
た。また、芯材として硬質ウレタンやＰＶＣフォームが
知られているが、これらは耐熱性が劣り、高温下で歪み
や変質が発生し、またスチレンフォームは、耐薬品性に
欠けるため、塗装や接着ができなかった。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.
【０００３】[0003]
【発明が解決しようとする課題】この発明は、不飽和ポ
リエステル樹脂やビニルエステル樹脂等の熱硬化性樹脂
に空気等を機械力で混入させて発泡させ、得られた未硬
化の発泡体を板状に成形し、硬化させることにより、表
面が緻密な表皮層で被覆され、従来の石材等に比べて軽
く、柔らかく、しかも強度に優れ、更に耐水性、耐熱性
および耐薬品性を備え、従来の石材、人造石、粘土製
品、石膏ボード、化粧ベニヤおよび発泡樹脂製品等に代
えて使用することができる板材を提供するものである。SUMMARY OF THE INVENTION The present invention relates to a thermosetting resin, such as an unsaturated polyester resin or a vinyl ester resin, which is mixed with air or the like by mechanical force to form a foam. By molding and curing, the surface is covered with a dense skin layer, and it is lighter, softer, and more excellent in strength than conventional stone materials, and has water resistance, heat resistance and chemical resistance. The present invention is to provide a plate material which can be used in place of stone, artificial stone, clay product, gypsum board, decorative veneer, foamed resin product and the like.
【０００４】[0004]
【課題を解決するための手段】上記の課題を解決するた
めの第１手段は、不飽和ポリエステル樹脂、ビニルエス
テル樹脂、エポキシ樹脂、フェノール樹脂およびフラン
樹脂の中の任意の熱硬化性樹脂からなる発泡プラスチッ
ク板を製造する方法において、上記発泡プラスチック板
の厚み方向片側部分に対応する箱形の上型および厚み方
向他側部分に対応する箱形の下型にそれぞれあらかじめ
熱硬化性樹脂と非引火性の圧縮ガスとを機械力で混合し
てなる未硬化の発泡プラスチックを充填し、次いで上記
の上型および下型を閉じて上記の発泡プラスチックを常
温下で硬化させることを特徴とする。A first means for solving the above-mentioned problems is to use an unsaturated polyester resin, vinyl ester
Ter resin, epoxy resin, phenol resin and furan
In a method of manufacturing a foamed plastic plate made of any thermosetting resin in a resin, a box-shaped upper die corresponding to one side portion in the thickness direction of the foamed plastic plate and a box-shaped portion corresponding to the other side portion in the thickness direction. Each lower mold is filled with uncured foamed plastic obtained by mixing a thermosetting resin and a non-flammable compressed gas with mechanical force in advance, and then the upper mold and the lower mold are closed to remove the foamed plastic. It is characterized by being cured at room temperature.
【０００５】第２手段は、不飽和ポリエステル樹脂、ビ
ニルエステル樹脂、エポキシ樹脂、フェノール樹脂およ
びフラン樹脂の中の任意の熱硬化性樹脂からなる発泡プ
ラスチック板を製造する方法において、上記発泡プラス
チック板の外形に対応する箱形の金型にあらかじめ熱硬
化性樹脂と非引火性の圧縮ガスとを機械力で混合してな
る未硬化の発泡プラスチックを充填し、次いで上記の金
型に充填された発泡プラスチックの表面を蓋板で被覆し
て上記の発泡プラスチックを常温下で硬化させることを
特徴とする。The second means is to use an unsaturated polyester resin,
Nyl ester resin, epoxy resin, phenol resin and
And a method of manufacturing a foamed plastic plate made of any thermosetting resin in furan resin, wherein a thermosetting resin and a non-flammable compressed gas are previously placed in a box-shaped mold corresponding to the outer shape of the foamed plastic plate. And filling the uncured foamed plastic obtained by mixing with a mechanical force , then covering the surface of the foamed plastic filled in the mold with a lid plate and curing the foamed plastic at room temperature. Features.
【０００６】上記の第１手段および第２手段において、
発泡プラスチック板の原料となる熱硬化性樹脂は、不飽
和ポリエステル樹脂、ビニルエステル樹脂（エポキシア
クリレート樹脂）、エポキシ樹脂、フェノール樹脂、フ
ラン樹脂等の通常の熱硬化性樹脂であり、用途に応じて
適宜に選択される。特に不飽和ポリエステル樹脂および
ビニルエステル樹脂は、常温硬化が可能であり、しかも
強度、耐熱性、耐水性および耐薬品性等に優れる点で好
ましい。なお、上記の不飽和ポリエステル樹脂は、イソ
フタル酸系、テレフタル酸系、ビスフェノール系、ヘッ
ト酸系等のいずれでもよく、ビニルエステル樹脂は、ビ
スフェノール系、ノボラック系等のいずれでもよい。In the first and second means,
The thermosetting resin used as the raw material of the foamed plastic plate is a normal thermosetting resin such as an unsaturated polyester resin, a vinyl ester resin (epoxy acrylate resin), an epoxy resin, a phenol resin, and a furan resin. It is appropriately selected. 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.
【０００７】第１手段では、箱形の上型および下型が用
いられる。上型は、製品となる発泡プラスチック板の厚
み方向片側部分に対応する箱形に、また下型は上記発泡
プラスチック板の厚み方向他側部分に対応する箱形にそ
れぞれ形成される。すなわち、上型および下型の両者を
合わせたとき、その内側空間（キャビティ）が製品とな
る発泡プラスチック板と同じ形状となるように作られ
る。この場合、上型および下型におけるキャビティの平
面形状は、正方形、長方形、円形、五角形等のいずれで
もよく、目的に応じて任意の形が選択される。また、上
型および下型は、平面形状および深さが必ずしも同一で
なくてもよく、目的に応じて相違させることができる。
また、キャビティの底面には任意の凹凸を設けることが
できる。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.
【０００８】上記の上型および下型には、前記の熱硬化
性樹脂および圧縮ガスの混合物である発泡プラスチック
が未硬化の状態で吹付けや注入によって充填される。上
記の混合物は、公知の方法、例えばビーナスガスマー社
の機械配合式発泡システム（ＭＢＦシステム）で作るこ
とができる。このＭＢＦシステムは、熱硬化性樹脂を圧
縮ガスと均一に混合して発泡させ、次いで硬化剤と混合
してスプレーまたは注型によって熱硬化性樹脂の発泡体
を成形し、常温で硬化する方法である。The above-mentioned upper mold and lower mold are filled with a foamed plastic which is a mixture of the above-mentioned thermosetting resin and compressed gas in an uncured state by spraying or pouring. 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.
【０００９】圧縮ガスは、非引火性であれば、任意のガ
ス、例えば炭酸ガス、窒素ガス、アルゴンガスおよび空
気等を用いることができる。そして、使用するガスや熱
硬化性樹脂の種類、圧力および添加剤の配合量等によっ
て気泡の構造や発泡プラスチック板の比重が調整され
る。例えば、不飽和ポリエステル樹脂やビニルエステル
樹脂を使用した場合、気泡を大きく、比重を０．２５〜
０．４０程度に小さくするには炭酸ガスが好ましく、反
対に気泡を小さく、比重を０．４０〜０．４５程度に大
きくするには窒素ガスが好ましい。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.
【００１０】上記の熱硬化性樹脂は、圧縮ガスと混合す
るに先立ち、その硬化開始温度よりも低い可塑化溶融温
度に加熱して粘度を低下させ、しかるのち圧縮ガスと混
合するのが好ましく、この場合は圧縮ガスとの混合が容
易になり、得られる発泡プラスチックの気泡が均一な大
きさになる。例えば、不飽和ポリエステル樹脂は、硬化
剤を入れなくても、高温になると硬化が始まるので、こ
の硬化開始温度よりも低い可塑化溶融温度３０〜５０℃
に加熱して粘度を低下させることが好ましい。また、こ
の加熱の際、発泡後の熱硬化性樹脂の硬化を助ける硬化
促進剤および気泡を消え難くするための整泡剤等を添加
することが好ましく、これによって圧縮ガスとの混合が
一層容易になり、しかも上型や下型に充填した際に大気
に触れて冷やされると、粘度が上昇して気泡が消え難く
なる。Prior to mixing with the compressed gas, the thermosetting resin is preferably heated to a plasticizing melting temperature lower than the curing start temperature to reduce the viscosity, and then mixed with the compressed gas. In this case, the mixing with the compressed gas becomes easy, and the bubbles of the obtained foamed plastic have a uniform size. For example, since the unsaturated polyester resin starts to be cured at a high temperature without adding a curing agent, the plasticization melting temperature 30 to 50 ° C. lower than the curing start temperature.
To lower the viscosity. In addition, at the time of this heating, it is preferable to add a curing accelerator for assisting the curing of the thermosetting resin after foaming, and a foam stabilizer for preventing bubbles from disappearing, so that mixing with the compressed gas is further facilitated. In addition, when the upper and lower molds are filled with air and cooled when exposed to the air, the viscosity increases and bubbles are difficult to disappear.
【００１１】上型および下型に上記の発泡プラスチック
が充填されると、この上型および下型が上記発泡プラス
チックを中にして合わせられ、この状態で常温下に放置
することにより、上記の発泡プラスチックが硬化され
る。そして、この硬化に伴って上型内の発泡プラスチッ
クと下型内の発泡プラスチックが互いに接着により一体
化される。その際、発泡プラスチックの上型および下型
に接する部分から気泡が消えて緻密な表皮層が形成され
る。したがって、上型および下型のキャビティを合わせ
た形の発泡プラスチック板であって、表面に緻密な表皮
層を有し、表皮層の内側の気泡が均一な発泡プラスチッ
ク板が得られる。なお、発泡プラスチックの充填後に直
ちに硬化が始まるように硬化剤や硬化促進剤等の配合量
を調整することにより、発泡プラスチック自体の重量で
気泡が破れるのを抑制し、表皮層の厚みを薄くすること
ができる。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. 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, a foamed plastic plate in which the cavities of the upper mold and the lower mold are combined, which has a dense skin layer on the surface and in which bubbles inside the skin layer are uniform, can be 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.
【００１２】この第１手段は、上型および下型の両者に
熱硬化性樹脂と圧縮ガスの混合物（発泡プラスチック）
を充填するので、比較的厚みの大きい発泡プラスチック
板を製造するのに適している。そして、この第１手段に
おいては、上型および下型の深さを相違させることがで
きる。また、上型および下型の外形（キャビティの輪
郭）を相違させ、一方の縁部を他方の縁部から突出させ
ることにより、縁部に段差のある発泡プラスチック板を
製造することができる。この場合、突出している側の発
泡プラスチック表面は、他方の縁部に続く平坦な金型表
面または蓋板で覆うことが好ましい。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.
【００１３】また、上型および下型を同じ正方形または
長方形に、かつ同じ深さに成形し、この上型および下型
に上記の発泡プラスチックを充填して合わせる際に、上
型と下型を長さ方向または幅方向にずらすことにより、
相欠き継ぎ用の段部を備えた発泡プラスチック板が得ら
れる。この場合も、突出する側の発泡プラスチック表面
は、他方の金型表面または蓋板で覆うことが好ましい。When the upper mold and the lower mold are formed into the same square or rectangle and at the same depth, and the above-mentioned upper mold and the lower mold are filled with the above-mentioned foamed plastic, 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.
【００１４】第２手段では、第１手段の下型に相当する
箱形の金型が１個と、その開口部を被覆する蓋板とが用
いられる。すなわち、製品となる発泡プラスチック板の
外形に対応する箱形、換言すれば上記の発泡プラスチッ
ク板を収容できる底の浅い箱形の金型が用意される。こ
の場合、キャビティの平面形状は、正方形、長方形、円
形、五角形等のいずれでもよく、目的に応じて任意の形
が選択される。また、キャビティの底面には任意の凹凸
を設けることができる。In the second means, one box-shaped mold corresponding to the lower mold of the first means and a cover plate for covering the opening thereof are used. That is, a box-shaped mold corresponding to the outer shape of the foamed plastic plate as a product, in other words, a box-shaped mold having a shallow bottom that can accommodate the 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.
【００１５】上記金型の内側に熱硬化性樹脂および圧縮
ガスの混合物（発泡プラスチック）が前記同様に満たさ
れ、次いでこの発泡プラスチックを被覆する蓋板が重ね
られて上記の発泡プラスチックが硬化され、この硬化に
伴い、発泡プラスチックの金型内面および蓋板下面に接
する部分の気泡が消失して緻密な表皮層が形成され、そ
の内側に均一な気泡を有する発泡プラスチック板が得ら
れる。この第２手段は、第１手段に比べて薄手の発泡プ
ラスチック板を製造するのに適している。A mixture of a thermosetting resin and a compressed gas (foamed plastic) is filled inside the mold in the same manner as described above, and then a lid plate covering the foamed plastic is overlaid to cure the foamed plastic, Along with this curing, bubbles in the portion of the foamed plastic in contact with the inner surface of the mold and the lower surface of the lid plate disappear, forming a dense skin layer, and a foamed plastic plate having uniform bubbles inside is obtained. The second means is more suitable for producing a thin foamed plastic plate than the first means.
【００１６】[0016]
実施形態１ 図１に示す発泡プラスチック板１０は、不飽和ポリエス
テル樹脂の発泡体（発泡プラスチック）からなる長方形
の板である。図中、１１は緻密な表皮層、１２は発泡層
である。図２において、１３は上型、１４は下型であ
り、いずれもキャビティは上記の発泡プラスチック板１
０と同じ平面形状を有し、深さは発泡プラスチック板１
０の厚みの半分に形成されている。そして、上型１３
は、反転可能に形成される。Embodiment 1 A foam plastic plate 10 shown in FIG. 1 is a rectangular plate made of a foam (foam plastic) of an unsaturated polyester resin. In the figure, 11 is a dense skin layer, and 12 is a foam layer. In FIG. 2, 13 is an upper mold and 14 is a lower mold.
0 has the same plane shape as that of FIG.
It is formed to half the thickness of 0. And the upper mold 13
Are formed to be reversible.
【００１７】一方、外気温度３〜３０℃の室内に設置さ
れた樹脂タンク（図示されていない）に所定量の不飽和
ポリエステル樹脂、適量の整泡剤および硬化促進剤を投
入、攪拌する。そして、攪拌しながら樹脂温度を硬化開
始温度よりも低い可塑化溶融温度３０〜５０℃に上昇さ
せる。しかるのち、この粘度が低下した不飽和ポリエス
テル樹脂をビーナスガスマー社製の機械配合発泡装置に
供給し、該装置内のインラインヒータで温度を上記の可
塑化溶融温度に維持しながら圧力１０００〜５０００kp
a の非引火性ガス（例えば、窒素ガス）と混合する。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 charged into a resin tank (not shown) installed in a room having an outside air temperature of 3 to 30 ° C., and 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).
【００１８】得られた飽和ポリエステル樹脂と圧縮ガス
の混合物すなわち発泡プラスチックを、スプレーガンを
用いて硬化剤と混合しながら前記の上型１３および下型
１４に充填する。図２において、１５は上記不飽和ポリ
エステル樹脂と窒素ガスの混合物すなわち発泡プラスチ
ックである。続いて、図２に鎖線１３で示すように、上
型１３を反転して下型１４に重ね、常温下に放置して発
泡プラスチック１５を常温下で硬化させ、硬化の完了
後、上型１３を開いて硬化した発泡プラスチック板（図
１の１０参照）を取り出す。The mixture of the obtained saturated polyester resin and the compressed gas, that is, foamed plastic, is charged into the upper mold 13 and the lower mold 14 while mixing with a curing agent using a spray gun. In FIG. 2, reference numeral 15 denotes a mixture of the unsaturated polyester resin and nitrogen gas, that is, a foamed plastic. Subsequently, as shown by a chain line 13 in FIG. 2, the upper mold 13 is inverted and overlapped with the lower mold 14, and is left at normal temperature to cure the foamed plastic 15 at normal temperature. Is opened to take out the cured foamed plastic plate (see 10 in FIG. 1).
【００１９】実施形態２ 図３に示すように、前記実施形態１と同じ箱形の下型１
４に実施形態１の発泡プラスチック１５を硬化剤と混合
しながら充填し、この下型１４上に実施形態１の箱形の
上型１３に代えて平板状の上型１６を蓋板状に重ね、し
かるのち上記の発泡プラスチック１５を前記同様に常温
下で硬化させ、この硬化後に平板状の上型１６を開いて
表皮層と発泡層とからなる発泡プラスチック板を取り出
す。Embodiment 2 As shown in FIG. 3, the same box-shaped lower mold 1 as in Embodiment 1 is used.
4 is filled with the foamed plastic 15 of the first embodiment mixed with a curing agent, and a flat plate-shaped upper die 16 is stacked on the lower die 14 in place of the box-shaped upper die 13 of the first embodiment. Thereafter, the foamed plastic 15 is cured at room temperature in the same manner as described above, and after this curing, the flat upper mold 16 is opened to take out the foamed plastic plate composed of the skin layer and the foamed layer.
【００２０】実施形態３ 図４に示すように、箱形の上型１７のキャビティを実施
形態１の上型１３よりも狭い幅に形成する。下型１４
は、実施形態１と同様に形成する。この上型１７および
下型１４に、実施形態１と同様に発泡プラスチック１５
を硬化剤と混合しながら充填し、次いで上型１７を図示
のように反転し、鎖線のように下型１４に重ね、上型１
７の左右の平坦な縁板１７ａで下型１４の左右の縁部内
側の発泡プラスチック１５の表面を押さえ、上記の発泡
プラスチック１５を常温で硬化させる。Embodiment 3 As shown in FIG. 4, the cavity of the box-shaped upper die 17 is formed to have a width smaller than that of the upper die 13 of the first embodiment. Lower mold 14
Is formed in the same manner as in the first embodiment. The upper mold 17 and the lower mold 14 are provided with the foamed plastic 15 similarly to the first embodiment.
Is filled while mixing with the curing agent, and then the upper mold 17 is inverted as shown in the figure, and is stacked on the lower mold 14 as indicated by a dashed line.
The left and right flat edge plates 17a hold the surfaces of the foamed plastic 15 inside the left and right edges of the lower mold 14, and the foamed plastic 15 is cured at room temperature.
【００２１】得られた発泡プラスチック板は、表面全体
を被覆する緻密な表皮層とその内側の発泡層とからな
り、左右の縁部に相欠き継ぎ用の段部を備えている。し
たがって、この発泡プラスチック板を複数枚並べた際、
１枚ごとに上下の向きを反転することにより、段部と段
部を上下に重ねる相欠き継ぎが可能になる。なお、この
相欠き継ぎを行う際、上記段部の重なり面に必要に応じ
て発泡ゴムその他のシール用パッキングを挟むことがで
きる。The obtained foamed plastic plate is composed of a dense skin layer covering the entire surface and a foam layer inside the skin layer, and has a step portion for jointing at the left and right edges. Therefore, when arranging multiple foam plastic plates,
By reversing the vertical direction for each sheet, it is possible to perform a step-by-step splicing in which the step portions are vertically overlapped. At the time of performing the joint break, foam rubber or other sealing packing can be sandwiched between the overlapping surfaces of the step portions as necessary.
【００２２】実施形態４ 図２に示す同じ大きさの上型１３および下型１４に実施
形態１と同様に発泡プラスチック１５を硬化剤と混合し
ながら充填し、上型１３を反転して下型１４上に重ねる
際、上型１３を下型１４に対して左右の一方にずらし、
上型１３の縁から突出した下型１４の発泡プラスチック
１５表面を上型１３の縁板で押さえ、また下型１４の縁
から突出した上型１３の発泡プラスチック１５表面を下
型１４の縁板で押さえ、上記の発泡プラスチック１５を
常温で硬化させる。Embodiment 4 An upper mold 13 and a lower mold 14 having the same size as shown in FIG. 2 are filled with a foamed plastic 15 while mixing with a curing agent in the same manner as in the embodiment 1, and the upper mold 13 is inverted to form a lower mold. When stacking on the upper mold 14, the upper mold 13 is shifted to the left or right with respect to the lower mold 14,
The surface of the foamed plastic 15 of the lower mold 14 projecting from the edge of the upper mold 13 is pressed by the edge plate of the upper mold 13, and the surface of the foamed plastic 15 of the upper mold 13 projected from the edge of the lower mold 14 is edged by the edge plate of the lower mold 14. To cure the foamed plastic 15 at room temperature.
【００２３】得られた発泡プラスチック板は、表面全体
を被覆する緻密な表皮層とその内側の発泡層とからな
り、左右の縁部に相欠き継ぎ用の段部を備えているが、
左と右では上下の向きが反対になるため、発泡プラスチ
ック板を配列する際、上下の向きを考慮しなくても相欠
き継ぎが可能になる。The obtained foamed plastic plate is composed of a dense skin layer covering the entire surface and a foam layer inside the skin layer. The foamed plastic plate is provided with stepped joints at the left and right edges.
Since the upper and lower directions are opposite on the left and right sides, when arranging the foamed plastic plates, it is possible to perform the splicing without considering the upper and lower directions.
【００２４】実施形態５ 図５に示すように、上型１８のキャビティを実施形態１
と実施形態３の中間程度の幅に形成する。下型１４は、
実施形態１と同様に形成する。この上型１８および下型
１４に、実施形態１と同様に発泡プラスチック１５を硬
化剤と混合しながら充填し、次いで上型１８を反転して
下型１４に重ね、上型１８および下型１４のキャビティ
の右縁を揃え、上型１８の左側の平坦な縁板１８ａで下
型１４の左縁部内側の発泡プラスチック１５の表面を押
さえ、上記の発泡プラスチック１５を常温で硬化させ
る。Embodiment 5 As shown in FIG. 5, the cavity of the upper mold 18 is formed in Embodiment 1.
And a width about the middle of Embodiment 3. The lower mold 14 is
It is formed in the same manner as in the first embodiment. The upper mold 18 and the lower mold 14 are filled with the foamed plastic 15 mixed with the curing agent in the same manner as in the first embodiment, and then the upper mold 18 is turned over and stacked on the lower mold 14, and the upper mold 18 and the lower mold 14 are filled. The right edges of the cavities are aligned, and the surface of the foamed plastic 15 inside the left edge of the lower mold 14 is pressed by the flat edge plate 18a on the left side of the upper mold 18 to cure the foamed plastic 15 at normal temperature.
【００２５】得られた発泡プラスチック板は、表面全体
を被覆する緻密な表皮層とその内側の発泡層とからな
り、左側の縁部のみに相欠き継ぎ用の段部を有してい
る。したがって、実施形態４または５の発泡プラスチッ
ク板を配列した際、その両端に配置して相欠き継ぎを行
うことができる。The obtained foamed plastic plate is composed of a dense skin layer covering the entire surface and a foam layer inside the skin layer, and has a stepped portion at only the left edge for jointing. Therefore, when the foamed plastic plates of the fourth or fifth embodiment are arranged, they can be arranged at both ends to perform the joint joining.
【００２６】実施形態６ 図６に示すように、上型１９および下型２０の平面形状
を同じ長方形に形成する。ただし、上型１９は四周の縁
部に傾斜のある皿形に形成し、下型２０は上記の傾斜が
無く、深さが均一な箱形に形成する。そして、上記の上
型１９および下型２０に、実施形態１と同様に発泡プラ
スチック１５を硬化剤と混合しながら充填し、次いで上
型１９を反転して下型２４に重ね、上記の発泡プラスチ
ック１５を常温で硬化させる。Embodiment 6 As shown in FIG. 6, the upper mold 19 and the lower mold 20 are formed in the same rectangular plane shape. However, the upper mold 19 is formed in a dish shape with an inclination at four edges, and the lower mold 20 is formed in a box shape having the above-mentioned inclination and having a uniform depth. Then, the upper mold 19 and the lower mold 20 are filled with the foamed plastic 15 mixed with the curing agent in the same manner as in the first embodiment. 15 is cured at room temperature.
【００２７】得られた発泡プラスチック板は、表面全体
を被覆する緻密な表皮層とその内側の発泡層とからなる
長方形の板であり、相欠き継ぎ用の段部を有しないが、
その片面の縁部全体が傾斜しているので、この片面を装
飾面として多数枚配列して用いることができる。The obtained foamed plastic plate is a rectangular plate composed of a dense skin layer covering the entire surface and a foam layer on the inside thereof, and does not have a step portion for jointing.
Since the entire edge of one side is inclined, a large number of this one side can be arranged and used as a decorative surface.
【００２８】[0028]
実施例１ テレフタル酸系の不飽和ポリエステル樹脂（日本ユピカ
株式会社製、商品名「ユピカ６４００」）を用い、図１
に示される発泡プラスチック板１０（全厚３０mm、全幅
１０００mm、全長３０００mm、表皮層１１の厚み０．１
mm）を製造した。すなわち、図２の上型１３および下型
１４を同じ大きさに作った。Example 1 FIG. 1 was obtained using a terephthalic acid-based unsaturated polyester resin (trade name “Yupika 6400” manufactured by Nippon Yupika Co., Ltd.)
Foamed plastic plate 10 (total thickness 30 mm, total width 1000 mm, total length 3000 mm, thickness of skin layer 11 of 0.1
mm). That is, the upper mold 13 and the lower mold 14 of FIG.
【００２９】一方、常温下において、樹脂タンクに上記
のテレフタル酸系不飽和ポリエステル樹脂１００重量
部、整泡剤（日本ユピカ株式会社製、商品名「ユピカＳ
Ｔ−Ｖ）１重量部および１２％オクチル酸コバルト（硬
化促進剤）０．２５重量部を投入し、ゆっくり攪拌しな
がら樹脂タンクを加熱して上記樹脂の温度を５０℃まで
上昇させた。次いで、上記の不飽和ポリエステル樹脂を
ビーナスガスマー社製の機械配合発泡装置に供給し、該
装置内のインラインヒータで樹脂温度を４５℃に維持し
ながら、圧力３５００kpa の窒素ガスと混合し、不飽和
ポリエステル樹脂に微細な気泡を均一に発生させ、発泡
プラスチック１５とした。On the other hand, at room temperature, 100 parts by weight of the above-mentioned terephthalic acid-based unsaturated polyester resin was added to a resin tank, and a foam stabilizer (trade name "UPICA S" manufactured by Nippon Yupica Co., Ltd.)
(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 15.
【００３０】次いで、上記の発泡プラスチック１５をス
プレーアップ法で上記の上型１３および下型１４の内側
に吹付けて充填した。ただし、吹付けを行いながら、ス
プレーガンの入口側において、上記の発泡プラスチック
に硬化剤（日本油脂株式会社製、商品名「パーキュアー
ＨＢ」）を発泡樹脂の１００重量部当たり１重量部添加
した。そして、発泡プラスチック１５が充填された上型
１３を反転して下型１４上に重ね、両者の発泡プラスチ
ック１５を合体させて常温で硬化した。Next, the above-mentioned foamed plastic 15 was sprayed and filled inside the upper mold 13 and the lower mold 14 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 13 filled with the foamed plastic 15 was inverted and overlaid on the lower mold 14, and both foamed plastics 15 were united and cured at room temperature.
【００３１】得られた発泡プラスチック板１０の曲げ強
さは１７ kgf／mm2 で、ポリ塩化ビニル、ナイロン、Ａ
ＢＳ樹脂、ポリエチレン等の非発泡樹脂からなる板の曲
げ強さ６．０〜１１ kgf／mm2 よりも優れ、しかも比重
は０．４０で、上記非発泡樹脂の比重１．１〜１．５に
比べて著しく軽量であった。また、耐水性の表皮層１１
を有するため、表面が平滑で、内側の発泡層に水が吸収
されることはなく、発泡体自体が不飽和ポリエステル樹
脂そのものであるため、耐紫外線性や耐薬品性に優れ、
屋外での使用は勿論、腐食性ガスの発生する環境下でも
充分に使用することができる。The bending strength of the foamed plastic plate 10 obtained was 17 kgf / mm 2 , and polyvinyl chloride, nylon, A
The flexural strength of a plate made of a non-foaming resin such as BS resin or polyethylene is superior to 6.0 to 11 kgf / mm 2 , and the specific gravity is 0.40, and the specific gravity of the non-foaming resin is 1.1 to 1.5. It was significantly lighter than. In addition, the water-resistant skin layer 11
Because the surface is smooth, water is not absorbed by the inner foam layer, and since the foam itself is an unsaturated polyester resin itself, it has excellent ultraviolet resistance and chemical resistance,
It can be used not only outdoors but also in an environment where corrosive gas is generated.
【００３２】実施例２ 実施例１に用いた上型１３の底面に岩肌状の凹凸を形成
する以外は、上記の実施例１と同様にして、不飽和ポリ
エステル樹脂の発泡体からなり、全厚３０mm、全幅１０
００mm、全長３０００mm、表皮層の厚み０．１mmで、表
面に岩肌状の凹凸を有する壁板用の発泡プラスチック板
を製造した。Example 2 The same procedure as in Example 1 was carried out except that rock-like irregularities were formed on the bottom surface of the upper mold 13 used in Example 1. 30mm, overall width 10
A foamed plastic plate for a wall plate having a thickness of 00 mm, a total length of 3000 mm, and a skin layer thickness of 0.1 mm and having rock-like irregularities on the surface was manufactured.
【００３３】実施例３ 図３に示す金型１４として内法寸法が深さ１０mm、幅１
０００mm、長さ３０００mmで、その底面に岩肌状の凹凸
を形成したものを、また上型１６として平坦な蓋板状の
ものをそれぞれ用いる以外は、実施例１と同様にして、
不飽和ポリエステル樹脂の発泡体からなり、全厚１０m
m、全幅１０００mm、全長３０００mm、表皮層の厚み
０．１mmで、表面に岩肌状の凹凸を有する壁板用の発泡
プラスチック板を製造した。Embodiment 3 The inner dimensions of the mold 14 shown in FIG.
000 mm, 3000 mm in length, a rock-shaped irregularity formed on the bottom surface, and a flat lid plate-shaped one as the upper die 16, respectively, in the same manner as in Example 1,
Made of unsaturated polyester resin foam, total thickness 10m
m, a total width of 1,000 mm, a total length of 3,000 mm, a thickness of a skin layer of 0.1 mm, and a foamed plastic sheet for wallboard having rock-surface irregularities on the surface.
【００３４】[0034]
【発明の効果】この発明によれば、緻密な表皮層とその
内側の発泡層とからなる発泡プラスチック板であって、
従来の石材等に比べて軽く、柔らかく、しかも強度に優
れ、更に耐水性、耐熱性および耐薬品性を備え、従来の
石材、人造石、粘土製品、石膏ボード、化粧ベニヤおよ
び発泡樹脂製品等に代えて使用可能な板材が得られる。
しかも、長方形に限らず円形その他任意形状の発泡プラ
スチック板を製造することができ、その際に形状および
性能が均一になる。特に請求項１記載の発明によれば、
上記発泡プラスチック板に相欠き継ぎ用の段部のように
厚みの小さい部分が存在する板材も容易に製造すること
ができる。According to the present invention, there is provided a foamed plastic plate comprising a dense skin layer and a foam layer inside the skin layer,
Lighter, softer, stronger and more resistant to water, heat and chemicals than conventional stones, etc., and used for conventional stones, artificial stones, clay products, gypsum boards, decorative veneers, foam resin products, etc. A plate material that can be used instead 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. In particular, according to the first aspect of the present invention,
A plate material having a small thickness portion such as a step portion for a joint in the foamed plastic plate can be easily manufactured.
【００３５】また、請求項２に記載の発明は、厚みが小
さい所定形状の発泡プラスチック板を比較的簡単に製造
することができる。また、請求項３に記載の発明は、熱
硬化性樹脂を予熱して粘度を低下させるので、圧縮ガス
との混合が容易になる。また、請求項４に記載の発明
は、上記予熱の際に硬化促進剤および整泡剤を添加する
ので、圧縮ガスとの混合が一層容易になり、しかも気泡
が消え難くなって発泡プラスチックの気泡が更に均一に
形成される。According to the second aspect of the present invention, a foamed plastic plate having a small thickness and a predetermined shape can be manufactured relatively easily. According to the third aspect of the present invention, the viscosity is reduced by preheating the thermosetting resin, so that the mixing with the compressed gas becomes easy. Further, in the invention according to claim 4, 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, so that the bubbles of the foamed plastic are reduced. Are formed more uniformly.
【図１】実施形態１の発泡プラスチック板を示す断面図
である。FIG. 1 is a cross-sectional view illustrating a foamed plastic plate of a first embodiment.
【図２】実施形態１に用いる金型の断面図である。FIG. 2 is a sectional view of a mold used in the first embodiment.
【図３】実施形態２に用いる金型の断面図である。FIG. 3 is a sectional view of a mold used in a second embodiment.
【図４】実施形態３に用いる金型の断面図である。FIG. 4 is a sectional view of a mold used in a third embodiment.
【図５】実施形態５に用いる金型の断面図である。FIG. 5 is a sectional view of a mold used in a fifth embodiment.
【図６】実施形態６に用いる金型の断面図である。FIG. 6 is a sectional view of a mold used in a sixth embodiment.
１０：発泡プラスチック板 １１：緻密な表皮
層 １２：発泡層 １３、１６、１７、１８、１９：上型 １４、２０：下型 １５：発泡プラスチック（熱硬化性樹脂と圧縮ガスの混
合物） １７ａ：１８ａ：縁板10: foamed plastic plate 11: dense skin layer 12: foamed layer 13, 16, 17, 18, 19: upper mold 14, 20: lower mold 15: foamed plastic (mixture of thermosetting resin and compressed gas) 17a: 18a: Edge plate
───────────────────────────────────────────────────── フロントページの続き (51)Int.Cl.7 識別記号 ＦＩ Ｂ２９Ｌ 7:00 (56)参考文献 特開 平４−216834（ＪＰ，Ａ) 特開 昭54−129060（ＪＰ，Ａ) (58)調査した分野(Int.Cl.7，ＤＢ名) B29C 39/02 - 39/12 B29C 39/22 - 39/40 B29C 44/00,67/20 C08J 9/30 ──────────────────────────────────────────────────の Continuation of the front page (51) Int.Cl. 7 Identification code FIB29L 7:00 (56) References JP-A-4-216834 (JP, A) JP-A-54-129060 (JP, A) ( 58) Field surveyed (Int.Cl. 7 , DB name) B29C 39/02-39/12 B29C 39/22-39/40 B29C 44/00, 67/20 C08J 9/30
Claims (4)
ル樹脂、エポキシ樹脂、フェノール樹脂およびフラン樹
脂の中の任意の熱硬化性樹脂からなる発泡プラスチック
板を製造する方法において、上記発泡プラスチック板の
厚み方向片側部分に対応する箱形の上型および厚み方向
他側部分に対応する箱形の下型にそれぞれあらかじめ熱
硬化性樹脂と非引火性の圧縮ガスとを機械力で混合して
なる未硬化の発泡プラスチックを充填し、次いで上記の
上型および下型を閉じて上記の発泡プラスチックを常温
下で硬化させることを特徴とする発泡プラスチック板の
製造法。1. An unsaturated polyester resin, vinyl ester
Resin, epoxy resin, phenol resin and furan tree
In a method of manufacturing a foamed plastic plate made of any thermosetting resin in fat, a box-shaped upper die corresponding to one side in the thickness direction of the foamed plastic plate and a box-shaped corresponding to the other side in the thickness direction are formed. Each lower mold is filled with uncured foamed plastic obtained by mixing a thermosetting resin and a non-flammable compressed gas with mechanical force in advance, and then the upper mold and the lower mold are closed to remove the foamed plastic. A method for producing a foamed plastic plate, which is cured at room temperature.
ル樹脂、エポキシ樹脂、フェノール樹脂およびフラン樹
脂の中の任意の熱硬化性樹脂からなる発泡プラスチック
板を製造する方法において、上記発泡プラスチック板の
外形に対応する箱形の金型にあらかじめ熱硬化性樹脂と
非引火性の圧縮ガスとを機械力で混合してなる未硬化の
発泡プラスチックを充填し、次いで上記の金型に充填さ
れた発泡プラスチックの表面を蓋板で被覆して上記の発
泡プラスチックを常温下で硬化させることを特徴とする
発泡プラスチック板の製造法。2. An unsaturated polyester resin, vinyl ester
Resin, epoxy resin, phenol resin and furan tree
In a method for producing a foamed plastic plate made of any thermosetting resin in fat, a thermosetting resin is previously formed in a box-shaped mold corresponding to the outer shape of the foamed plastic plate.
A non-flammable compressed gas is mixed with uncured foamed plastic by mechanical force, and then the surface of the foamed plastic filled in the mold is covered with a cover plate to cool the foamed plastic at room temperature. A method for producing a foamed plastic plate, which is cured under the following conditions.
ック板の製造法において、熱硬化性樹脂を圧縮ガスと混
合するに先立ち、上記熱硬化性樹脂をその硬化開始温度
よりも低い可塑化溶融温度に加熱して粘度を低下させ、
しかるのち圧縮ガスと混合する発泡プラスチック板の製
造法。3. The method for producing a foamed plastic sheet according to claim 1, wherein the thermosetting resin is plasticized and melted at a temperature lower than its curing start temperature before the thermosetting resin is mixed with the compressed gas. Heat to temperature to reduce viscosity,
Thereafter, a method of manufacturing a foamed plastic plate mixed with a compressed gas.
製造法において、熱硬化性樹脂を可塑化溶融温度に加熱
する際に硬化促進材および気泡を消え難くするための整
泡剤を添加、混合する発泡プラスチック板の製造法。4. The method for producing a foamed plastic sheet according to claim 3, 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.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP09127934A JP3073707B2 (en) | 1997-04-30 | 1997-04-30 | Manufacturing method of foam plastic plate |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP09127934A JP3073707B2 (en) | 1997-04-30 | 1997-04-30 | Manufacturing method of foam plastic plate |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| JPH10296769A JPH10296769A (en) | 1998-11-10 |
| JP3073707B2 true JP3073707B2 (en) | 2000-08-07 |
Family
ID=14972258
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP09127934A Expired - Fee Related JP3073707B2 (en) | 1997-04-30 | 1997-04-30 | Manufacturing method of foam plastic plate |
Country Status (1)
| Country | Link |
|---|---|
| JP (1) | JP3073707B2 (en) |
Families Citing this family (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN109094062A (en) * | 2018-08-04 | 2018-12-28 | 滁州晶田新型装饰材料有限公司 | A kind of WPC floor producing technology of antimycotic long-life |
-
1997
- 1997-04-30 JP JP09127934A patent/JP3073707B2/en not_active Expired - Fee Related
Also Published As
| Publication number | Publication date |
|---|---|
| JPH10296769A (en) | 1998-11-10 |
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