JP6643660B2 - Building member and artificial marble and building material integrated lighting device using the same - Google Patents

Description

  The present invention relates to a building member, and an artificial marble and a building material-integrated lighting device using the building member.

  BACKGROUND ART Conventionally, artificial marble made of resin having the same material, texture, and natural feeling as natural marble has been used. Such artificial marble is widely used in building materials for houses and the like, as well as counters for system kitchens, baths, vanities, and the like, because of its high design properties.

  Conventionally, as such a counter using artificial marble, a counter provided with a light-transmitting layer provided on the front surface side and transmitting light and a shielding layer provided to shield the back side of the light-transmitting layer is disclosed. (For example, see Patent Document 1). Further, the counter is provided at an interface between the light transmitting layer and the shielding layer, and has a light guide layer having a light incident portion at one end and a light emitting surface at the interface with the light transmitting layer. The light-transmitting layer, the light-guiding layer, and the shielding layer are integrated into a three-layer structure. With such a configuration, light propagates in the light guide layer and light is emitted from the light transmitting layer, so that a counter having a multilayer structure can provide a sense of depth and a three-dimensional effect.

JP 2011-67444A

  However, since the counter disclosed in Patent Document 1 has a three-layer structure in which the light-transmitting layer, the light-guiding layer, and the shielding layer are integrated, there is a problem that the thickness is increased by stacking. In addition, since it is necessary to manufacture the light transmitting layer, the light guiding layer, and the shielding layer, there is a problem that the number of manufacturing processes increases.

  The present invention has been made in view of such problems of the related art. An object of the present invention is to provide a building member that can be easily manufactured while suppressing an increase in thickness, and an artificial marble and a building material integrated lighting device using the same.

  In order to solve the above problems, a building member according to a first aspect of the present invention is formed of a first resin phase formed of a first resin and a second resin different from the first resin, A phase separation structure having a three-dimensionally continuous second resin phase inside the phase; The first resin phase is a light transmitting phase that transmits light, and the second resin phase is a light guiding phase that propagates incident light.

  The artificial marble according to the second aspect of the present invention comprises the above-described building member.

  A building material-integrated lighting device according to a third aspect of the present invention includes the above-described building member and a light source that emits light to a light guide phase of the building member.

  ADVANTAGE OF THE INVENTION According to this invention, since a building member can be formed by a single layer, it becomes possible to manufacture easily, suppressing increase in thickness. Further, the artificial marble and building material-integrated lighting device uses a single-layer building member, so that it is space-saving and has excellent design properties.

It is a schematic sectional view showing the building member concerning this embodiment, (a) is a schematic sectional view showing an example of the building member, and (b) is a schematic sectional view showing another example of the building member. . It is the schematic for demonstrating the phase separation structure of the building member which concerns on this embodiment, (a) shows a sea-island structure, (b) shows a continuous spherical structure, (c) shows a composite dispersion structure, (D) shows a bicontinuous structure. It is a schematic diagram for explaining the manufacturing process of the building member concerning this embodiment. It is the schematic for demonstrating the manufacturing process of the building member which does not have a phase separation structure. It is a schematic sectional drawing which shows the building material integrated lighting fixture which concerns on this embodiment, (a) is a schematic sectional drawing which shows an example of the said building material integrated lighting fixture, (b) is other than the said building material integrated lighting fixture. It is a schematic sectional drawing which shows the example of. It is a schematic diagram showing the example of application of the building material integrated lighting fixture concerning this embodiment. It is a photograph which shows the building member of an Example.

  Hereinafter, the building member according to the present embodiment and the artificial marble and building material integrated lighting fixture using the building member will be described in detail. Note that the dimensional ratios in the drawings are exaggerated for the sake of explanation, and may differ from the actual ratios.

[Building components]
As shown in FIG. 1A, the building member 10 according to the present embodiment is formed of a first resin phase 1 formed of a first resin, and a second resin different from the first resin, and a first resin phase. A phase separation structure having a second resin phase 2 that is three-dimensionally continuous inside the phase 1 is provided.

  The building member 10 of the present embodiment has a first resin phase 1 and a second resin phase 2, and further has a structure in which these resin phases are mixed and phase separated. Here, examples of the phase separation structure include at least one of a sea-island structure, a continuous spherical structure, a composite dispersion structure, and a bicontinuous structure. As shown in FIG. 2A, the sea-island structure refers to a structure in which a dispersed phase 2A having a small volume is dispersed in a continuous phase 1A, in which a particulate or spherical dispersed phase 2A is scattered in the continuous phase 1A. It is. As shown in FIG. 2 (b), the continuous spherical structure is a structure in which substantially spherical dispersed phases 2A are connected and dispersed in the continuous phase 1A. As shown in FIG. 2 (c), the composite dispersed structure is a structure in which the dispersed phase 2A is dispersed in the continuous phase 1A, and the resin constituting the continuous phase 1A is dispersed in the dispersed phase 2A. The bicontinuous structure is a structure in which the continuous phase 1A and the dispersed phase 2A form a complicated three-dimensional network as shown in FIG. In addition, the phase-separated structure such as the sea-island structure, the continuous spherical structure, the composite dispersion structure, and the bicontinuous structure are controlled by controlling curing conditions such as a curing speed and a reaction temperature of the resin molded product, compatibility of the resin, and a mixing ratio. Obtainable.

  In the building member 10 of the present embodiment, the second resin phase 2 is three-dimensionally continuous inside the first resin phase 1. Therefore, it is preferable that the first resin phase 1 and the second resin phase 2 have a co-continuous structure forming a complicated three-dimensional network.

  In the building member 10, the first resin phase 1 is a light transmitting phase that transmits light, and the second resin phase 2 is a light guiding phase that transmits incident light. That is, as described later, when light is incident from the light incident portion 2a of the second resin phase 2 using the light source 20 provided at one end of the building member 10, the incident light is changed to the first resin phase 1. And the second resin phase 2 reflects at the interface. Then, by repeating this reflection, the incident light propagates toward the end opposite to the light incident portion 2a. At this time, part of the propagating light is emitted from the interface between the first resin phase 1 and the second resin phase 2, transmitted through the first resin phase 1, and emitted from the surface of the building member 10. Thereby, it is possible to make the appearance such that a deep part of the building member 10 emerges, and it is possible to effectively express a three-dimensional effect.

  Further, in the building member 10, the first resin phase 1 and the second resin phase 2 have different optical characteristics. That is, the first resin phase 1 and the second resin phase 2 are different from each other, for example, in at least one of light transmittance, light refractive index, and color. For this reason, since the three-dimensional pattern derived from the shapes of the first resin phase 1 and the second resin phase 2 that are phase-separated is formed on the building member 10, it is possible to enhance the design even when light is not incident. Becomes possible.

  In the building member 10, the second resin preferably has a higher refractive index than the first resin. Such a difference in the refractive index makes it easy for light to be reflected at the interface between the first resin phase 1 and the second resin phase 2, so that light propagates inside the second resin phase 2 which is a light guiding phase. It will be easier. Therefore, it is possible to further enhance the three-dimensional appearance of the building member 10 as a whole. The refractive indexes of the first resin phase 1 and the second resin phase 2 can be measured as follows. First, each of the first resin phase 1 and the second resin phase 2 is shaved into a powder and dispersed in a solution having a different refractive index. Then, by measuring the refractive index of the solution of each phase that has become transparent, the refractive index of each phase can be estimated. The refractive index of the first resin phase 1 and the second resin phase 2 can also be obtained by the method B of Japanese Industrial Standard JIS K7142 (plastic-method for obtaining the refractive index).

  As shown in FIG. 1 (b), the building member 10A is provided on the back surface 10a of the phase separation structure, and reflects light from the first resin phase 1, which is a light transmitting phase, to reflect the light on the front surface 10b. May be provided. By providing such a reflective layer 3, it is possible to suppress the emission from the back surface 10a of the building member 10A and efficiently radiate it from the front surface 10b. The resin used for the reflective layer 3 is not particularly limited, but it is preferable to use a white resin to which a white pigment such as titanium oxide is added.

  In the building member 10, the size of the phase separation structure is not particularly limited, but is preferably, for example, not less than the wavelength of visible light. That is, the size of the phase separation structure is preferably 380 nm or more. When the size of the phase separation structure is 380 nm or more, light propagates inside the second resin phase 2 which is a light guiding phase, and thus can be radiated from the entire building member 10. Note that the size of the phase separation structure refers to the width d of the second resin phase 2 (dispersed phase 2A) as shown in FIGS. 1A and 2D. Note that the size of the phase separation structure is more preferably 1 μm or more, and further preferably 0.5 mm or more. In addition, the size of the phase separation structure is preferably 1 mm or more, more preferably 2 mm or more, further preferably 5 mm or more, and particularly preferably 10 mm or more. When the size of the phase separation structure is 0.5 mm or more, the boundary between the first resin phase 1 and the second resin phase 2 can be visually discriminated, so that the pattern formed on the building member 10 is recognized, It is also possible to enhance the performance. The upper limit of the size of the phase separation structure is not particularly limited, but may be, for example, 300 mm.

  In the building member 10, the first resin phase 1 preferably includes an acrylic phase derived from methyl methacrylate. That is, the first resin phase 1 preferably contains an acrylic resin phase obtained by polymerizing methyl methacrylate. When the first resin phase 1 contains the acrylic phase, the resulting building member 10 has a good appearance, and also has sufficient strength such as heat resistance and water resistance.

  Further, the first resin phase 1 preferably contains polymethyl methacrylate. When the first resin phase 1 contains polymethyl methacrylate, the strength of the first resin phase 1 can be further increased. Further, when the first resin phase 1 contains both polymethyl methacrylate and an acrylic phase derived from methyl methacrylate, a phase separation structure is easily formed. The weight average molecular weight of the polymethyl methacrylate is not particularly limited, but is preferably, for example, 1,000 to 500,000, and more preferably 50,000 to 200,000. The weight average molecular weight is a value in terms of polystyrene measured by GPC (gel permeation chromatography).

  The first resin constituting the first resin phase 1 is a three-dimensional polymethyl methacrylate obtained by polymerizing methyl methacrylate with a crosslinking agent described later, and a polymethyl methacrylate different from the three-dimensional polymethyl methacrylate. Is more preferably an acrylic resin obtained by mixing Thereby, the building member 10 has a good appearance and has a sufficient strength. In addition, since the first resin phase 1 and the second resin phase 2 are easily separated from each other, a three-dimensional light guide phase can be easily formed.

  Note that, as described later, the first resin phase 1 may include a filler or the like. However, the first resin phase 1 has an acrylic phase formed by mixing three-dimensional polymethyl methacrylate obtained by polymerization of methyl methacrylate and polymethyl methacrylate different from the three-dimensional polymethyl methacrylate. It is preferably the main component.

  The second resin constituting the second resin phase 2 is preferably made of a material that is phase-separated from the first resin. By using such a material as the second resin, the first resin phase 1 and the second resin phase 2 can be easily phase-separated.

  As the second resin constituting the second resin phase 2, the following polymers can be used. For example, at least one selected from the group consisting of polystyrene, poly (meth) acrylate, polyvinyl acetate, polybutadiene, polyisoprene, and polyvinyl chloride can be used. In addition, as the polymer, a random copolymer, a block copolymer or a graft copolymer of polystyrene, poly (meth) acrylate, polyvinyl acetate, polybutadiene, polyisoprene, or polyvinyl chloride can also be used. . Examples of such a polymer include acrylate polymer AS-3000 (manufactured by Negami Kogyo Co., Ltd.) (skeleton main composition: butyl acrylate, functional group type: OH, molecular weight: 120000 to 1300000, weight average molecular weight Mw: 650,000).

  The second resin phase 2 may be formed by polymerizing the second resin precursor and methyl methacrylate. In other words, the second resin constituting the second resin phase 2 may be a copolymer of the second resin precursor and methyl methacrylate. Therefore, the second resin precursor preferably has a substituent polymerizable with methyl methacrylate. As such a second resin precursor, for example, at least one of the following monomers and oligomers can be used.

  As the monomer as the second resin precursor, at least one selected from the group consisting of a monofunctional styrene monomer, a methacrylate ester, an acrylate ester, a vinyl ester monomer, and a conjugated diene monomer can be used.

  Examples of the styrene monomer include styrene, α-methylstyrene, p-methylstyrene, and p-methoxystyrene.

  Examples of the methacrylate include methyl methacrylate, ethyl methacrylate, n-propyl methacrylate, n-butyl methacrylate, isobutyl methacrylate, n-pentyl methacrylate, n-hexyl methacrylate, and methacrylic acid. Of methacrylic acid and aliphatic hydrocarbon such as n-heptyl acid, n-octyl methacrylate, 2-ethylhexyl methacrylate, nonyl methacrylate, decyl methacrylate, dodecyl methacrylate, and stearyl methacrylate Esters can be mentioned. The aliphatic hydrocarbon preferably has 1 to 18 carbon atoms. Examples of the methacrylate include alicyclic methacrylates such as cyclohexyl methacrylate and isobornyl methacrylate; aralkyl methacrylates such as benzyl methacrylate; phenyl methacrylate, and toluyl methacrylate. Methacrylic acid aromatic hydrocarbon esters; esters of methacrylic acid such as 2-methoxyethyl methacrylate and 3-methoxybutyl methacrylate with a functional group-containing alcohol having ethereal oxygen. Further, as the methacrylate, trifluoromethyl methacrylate, trifluoromethylmethyl methacrylate, 2-trifluoromethylethyl methacrylate, 2-trifluoroethyl methacrylate, 2-perfluoroethyl methacrylate Ethyl, 2-perfluoroethyl methacrylate-2-perfluorobutylethyl, 2-perfluoroethyl methacrylate, perfluoromethyl methacrylate, diperfluoromethylmethyl methacrylate, 2-perfluoromethacrylate Alkyl fluoroesters such as methyl-2-perfluoroethylmethyl, 2-perfluorohexylethyl methacrylate, 2-perfluorodecylethyl methacrylate, and 2-perfluorohexadecylethyl methacrylate It can be also mentioned.

  Examples of the acrylate include methyl acrylate, ethyl acrylate, n-propyl acrylate, n-butyl acrylate, isobutyl acrylate, n-pentyl acrylate, n-hexyl acrylate, n-heptyl acrylate, and acrylic acid Esters of acrylic acid and aliphatic hydrocarbon such as n-octyl, 2-ethylhexyl acrylate, nonyl acrylate, decyl acrylate, dodecyl acrylate, stearyl acrylate and the like can be mentioned. The aliphatic hydrocarbon preferably has 1 to 18 carbon atoms. Examples of the acrylate include acrylic alicyclic hydrocarbon esters such as cyclohexyl acrylate and isobornyl acrylate; aromatic acrylate aromatic hydrocarbon esters such as phenyl acrylate and toluyl acrylate; and acrylic acids such as benzyl acrylate Aralkyl esters; esters of acrylic acid such as 2-methoxyethyl acrylate and 3-methoxybutyl acrylate with a functional group-containing alcohol having ethereal oxygen. Further, as the acrylate, trifluoromethylmethyl acrylate, 2-trifluoromethylethyl acrylate, 2-perfluoroethylethyl acrylate, 2-perfluoroethyl-2-perfluorobutylethyl acrylate, acrylic acid 2-perfluoroethyl, perfluoromethyl acrylate, diperfluoromethylmethyl acrylate, 2-perfluoromethyl-2-perfluoroethylmethyl acrylate, 2-perfluorohexylethyl acrylate, 2-perfluoro acrylate Fluorinated alkyl acrylates such as decylethyl and 2-perfluorohexadecylethyl acrylate can also be mentioned. Acrylic esters also include tricyclodecane dimethanol diacrylate.

  Examples of the vinyl ester monomer include vinyl acetate, vinyl propionate, vinyl pivalate, vinyl benzoate, vinyl cinnamate and the like. Examples of the conjugated diene-based monomer include butadiene and isoprene.

  Further, as the monomer that is the second resin precursor, a bifunctional or polyfunctional acrylic carboxylic acid ester monomer can be used. Examples of such a monomer include an acrylic monomer and a methacrylate monomer.

  Examples of acrylic monomers include, for example, ethylene glycol diacrylate, tetraethylene glycol diacrylate, nonane ethylene glycol diacrylate, tetradecane ethylene glycol diacrylate, 1,3-butylenediol diacrylate, 1,6-hexanediol diacrylate, Neopentyl glycol diacrylate, polypropylene glycol diacrylate, o-diallyl phthalate, m-diallyl phthalate, 2,2′-bis (4-acryloxydiethoxyphenyl) propane, trimethylolpropane triacrylate, trimethylolethane triacrylate, Tetramethylol methane tetraacrylate, bisphenol A polyethylene glycol diacrylate, ethane diglycidyl ether di Acrylate, 2-propanol diglycidyl ether diacrylate, 1,6-hexanediurethane polyethylene glycol diacrylate, xylylene urethane diacrylate, 1,6-hexanediurethane glycerin tetraacrylate, 1,6-hexanediurethanephthalic acid Diacrylate, bisphenol A-hexane diurethane diethyl acrylate, glycidol diacrylate, glycerin diacrylate, glycerin triacrylate, bisphenol A diacrylate, xylylene glycol diacrylate, hydroquinone diacrylate, resorcin diacrylate, cyclohexane dimethanol diacrylate Acrylate, triallyl cyanurate, diallyl diglycol carbonate, diallyl dibutyl phosphonosuccine Door, and the like Kyoeisha Chemical Co., Ltd. Epolight 3002A. Those obtained by substituting at least one of the acrylate groups of these monomers with a methacryl group may be used.

  Examples of the methacrylate monomer include, for example, cyclohexane dimethanol dimethacrylate, ethylene glycol dimethacrylate, diethylene glycol dimethacrylate, triethylene glycol dimethacrylate, tetraethylene glycol dimethacrylate, nonaneethylene glycol dimethacrylate, tetradecane ethylene glycol dimethacrylate, 1,3-butanediol dimethacrylate, butanediol dimethacrylate, 1,6-hexanediol dimethacrylate, neobentyl glycol dimethacrylate, dipropylene glycol dimethacrylate, nonanepropylene glycol dimethacrylate, bisphenol A tetraethylene glycol dimethacrylate, Trimethylolpropane trimeta Relate, tetramethylolethanetrimethacrylate, trimethylolethanetrimethacrylate, ethaneglycidyl ether dimethacrylate, 2,2′-bis (4-methacryloxydiethoxyphenyl) propane, bisphenol glycidyl ether dimethacrylate, bisphenol polyethylene glycol dimethacrylate, 2 -Propanol diglycidyl ether dimethacrylate, 1,6-hexanediurethane polyethylene glycol dimethacrylate, xylylene diurethane dimethacrylate, 1,6-hexanediurethane glycerin tetramethacrylate, glycidol dimethacrylate, glycerin dimethacrylate, glycerin trimethacrylate, bisphenol A dimethacrylate, xylylene glycol dime Acrylate, hydroquinone dimethacrylate, resorcin dimethacrylate, cyclohexane dimethanol dimethacrylate, triethylene methallyl cyanurate, dimethallyl diglycol carbonate, and the like manufactured by Kyoeisha Chemical Co., Ltd. Epolight 3002M. Those in which one or more of the methacrylate groups of these monomers are substituted with an acrylate group may be used.

  In addition, the above-mentioned monomers may be used alone or in a combination of two or more. From the viewpoint of improving the heat resistance of the obtained building member 10, the monomer that is the second resin precursor is preferably an alicyclic (meth) acrylate hydrocarbon ester.

  The oligomer that is the second resin precursor has an acrylate oligomer, a urethane acrylate oligomer, an epoxy acrylate oligomer, a polyester acrylate oligomer, a polyether acrylate oligomer, a diene polymer acrylate oligomer, and a hydrogenated skeleton of a diene polymer acrylate. At least one selected from the group consisting of oligomers can be used.

  Examples of the acrylate oligomer include Actflow (registered trademark) UT-1001 (manufactured by Soken Chemical Co., Ltd.) (polyfunctional hydroxyl acrylate, skeleton main component: 2-ethylhexyl acrylate, weight average molecular weight: about 3500). Examples of the acrylate oligomer include Actflow CB-3060 (polyfunctional carboxyl acrylate, skeleton main component: 2-ethylhexyl acrylate, weight average molecular weight: about 3000) manufactured by Soken Chemical Co., Ltd. In addition, examples of the acrylate oligomer include an acrylic oligomer EBECRYL (registered trademark) 767 (weight average molecular weight: about 12000) manufactured by Daicel Ornex.

  Examples of the urethane acrylate oligomer include UN-7700 (manufactured by Negami Industry Co., Ltd.) (skeleton main component: polyester, weight average molecular weight: about 20,000). Examples of urethane acrylate oligomer include EBECRYL4491 (weight average molecular weight: about 7000) manufactured by Daicel Ornex. Examples of the urethane acrylate oligomer include EBECRYL230 (skeleton main component: aliphatic, weight average molecular weight: about 5000) manufactured by Daicel Ornex.

  The above oligomers may be used alone or in combination of two or more. The oligomer preferably has a reactive group in terms of heat resistance and long-term reliability. Further, since an oligomer having a functional group easily forms a phase separation structure, it is preferable to use such an oligomer as the second resin precursor.

  It is more preferable that the second resin contains at least one selected from the group consisting of a (meth) acrylate monomer, a (meth) acrylate oligomer and a (meth) acrylate polymer. As a result, the obtained second resin phase also becomes an acrylic phase, so that the obtained building member 10 has a good appearance and has a sufficient strength. The “(meth) acrylate monomer” refers to the above-mentioned methacrylate-based monomer and acrylic monomer. The “(meth) acrylate oligomer” is obtained by polymerizing or copolymerizing a (meth) acrylate monomer. The (meth) acrylate polymer is obtained by polymerizing or copolymerizing a (meth) acrylate monomer or a (meth) acrylate oligomer.

  Note that the second resin phase 2 may also contain a filler or the like, but it is preferable that the second resin phase 2 is also mainly composed of an acrylic phase made of an acrylic resin.

  In the building member 10 of the present embodiment, at least one of the first resin phase 1 and the second resin phase 2 may include a filler. By containing a filler, it is possible to enhance the design of the building member 10 and the diffusivity of incident light. In addition, the filler may be contained in only one of the first resin phase 1 and the second resin phase 2 or may be contained in both. Further, it may be partially contained in the first resin phase 1 and the second resin phase 2.

The filler is not particularly limited, but an inorganic compound can be used. Examples of the inorganic compound include borides, carbides, nitrides, oxides, silicides, hydroxides, carbonates, and the like. Specific examples include magnesium oxide (MgO), aluminum oxide (Al ₂ O ₃ ), boron nitride (BN), aluminum nitride (AlN), and aluminum hydroxide (Al (OH) ₃ ). In addition, silicon dioxide (SiO ₂ ), magnesium carbonate (MgCO ₃ ), magnesium hydroxide (Mg (OH) ₂ ), calcium carbonate (CaCO ₃ ), clay, talc, mica, titanium oxide (TiO ₂ ), zinc oxide ( ZnO) and the like.

  Further, a carbon material can be used as the filler. As the carbon material, for example, at least one selected from the group consisting of carbon black, activated carbon, and fullerene can be used. In addition, as carbon black, at least one selected from the group consisting of Ketjen Black (registered trademark), acetylene black, channel black, lamp black, oil furnace black, and thermal black can be used.

  The shape of the carbon material is not limited to the particle shape, and may be, for example, a wire shape or a flake shape. Examples of the wire-like carbon material include at least one selected from the group consisting of carbon nanotubes, carbon nanofibers, carbon nanohorns, and carbon fibrils. As the flaky carbon material, graphene having a thickness of 0.05 μm to 1 μm and an aspect ratio of about 10 to 1000 can be used. The aspect ratio means an average plane diameter D (average plane diameter / thickness) with respect to the thickness of graphene.

  In the building member 10 of the present embodiment, at least one of the first resin phase 1 and the second resin phase 2 may include at least one of a pigment and a dye. The pigments and dyes are not particularly limited, but for example, organic pigments, inorganic pigments, dyes and the like can be used. Examples of the organic pigment include phthalocyanine, benzimidazolone, azo, azomethine azo, azomethine, anthraquinone, perinone / perylene, indigo / thioindigo, dioxazine, quinacridone, isoindoline, and isoindoline. Indolinone pigments, carbon black pigments, and the like. Examples of the inorganic pigment include extender pigments, titanium oxide pigments, iron oxide pigments, and spinel pigments. More specifically, insoluble azo pigments such as toluidine red, toluidine maroon, hansa yellow, benzidine yellow, pyrazolone red, soluble azo pigments such as lithol red, helio bordeaux, pigment scarlet, permanent red 2B, phthalocyanine blue, phthalocyanine green, etc. Quinacridones such as phthalocyanine, quinacridone red and quinacridone magenta; perylenes such as perylene red and perylene scarlet; isoindolinones such as isoindolinone yellow and isoindolinone orange; pyranthrones such as pyranthrone red and pyranthrone orange. , Thioindigo, condensed azo, benzimidazolone, quinophthalone yellow, nickel azo yellow, perinone orange, anthrone orange, diansura Nonirureddo, pigments such as dioxazine violet can be used.

  As the dye, for example, a direct dye, a basic dye, a cationic dye, an acid dye, a mordant dye, an acid mordant dye, a sulfur dye, a naphthol dye, a disperse dye, a reactive dye, and the like can be used.

  In addition, from the viewpoint of improving the dispersibility in the first resin phase and the second resin phase, the particle size of the filler is preferably 0.01 μm to 100 μm, more preferably 5 μm to 50 μm. The particle diameter and aspect ratio of the filler can be determined by observing the building member 10 with a scanning electron microscope (SEM) or a transmission electron microscope (TEM).

  The building member 10 of the present embodiment can include other components in addition to the above components, as long as the effects of the present embodiment are not impaired. Such other components include, for example, an internal release agent such as stearic acid and zinc stearate, a functional resin such as a fluororesin or a silicone resin, a flame retardant, a flame retardant auxiliary, and a viscosity control in production. And a dispersing agent for improving the dispersibility of the filler can also be blended. These can use a well-known thing.

  Next, a method for manufacturing the building member 10 of the present embodiment will be described. For convenience of description, a case where methyl methacrylate and polymethyl methacrylate are used as a precursor of the first resin will be described.

  First, methyl methacrylate, polymethyl methacrylate, a second resin precursor composed of at least one of the above monomers and oligomers, and a polymerization initiator are mixed to produce an uncured resin composition. Also, an uncured resin composition can be produced by mixing methyl methacrylate, polymethyl methacrylate, the second resin composed of the above-mentioned polymer, and a polymerization initiator. At this time, a crosslinking agent may be contained in order to promote a crosslinking reaction when the methyl methacrylate and the second resin precursor are polymerized. The mixing of the components may be performed in one stage, or the components may be sequentially added and performed in multiple stages. When each component is added sequentially, they can be added in any order, but from the viewpoint of storage stability of the resin composition, it is preferable to add the polymerization initiator last. The mixing temperature at the time of producing the resin composition is not particularly limited as long as mixing can be performed, but may be, for example, room temperature (about 15 to 35 ° C.).

  As described above, if necessary, additives such as an internal release agent, a functional resin, a flame retardant, a flame retardant auxiliary, a viscosity reducing agent, a dispersion modifier, and a polymerization inhibitor are added to the resin composition. May be. The order of adding these additives is not particularly limited, and they can be added at any stage. However, as described above, it is preferable to add the polymerization initiator last.

  As the mixing machine used for the production of the resin composition, a conventionally known mixing machine can be used. Specific examples include a planetary mixer, a kneader, a Banbury mixer, a mixing container provided with a stirring blade, a horizontal mixing tank, and the like.

  Then, the uncured resin composition is formed into a desired shape. The molding method of the uncured resin composition can be any method, and the molding shape can be any shape. For example, various means such as compression molding (direct pressure molding), transfer molding, injection molding, extrusion molding, cast molding, and screen printing can be used as the molding means.

  After the molding, the building member 10 of the present embodiment can be obtained by heating the uncured resin composition to cause the curing reaction to proceed. The heating condition of the resin composition is not particularly limited, but it is preferable to heat the resin composition at, for example, 60 to 150 ° C. for 0.1 to 4 hours.

  As the cross-linking agent used in the polymerization reaction, any conventionally known one can be used as long as it is a thermosetting cross-linking agent. For example, an acrylic compound can be used. As the acrylic compound, for example, trimethylolpropane triacrylate, ditrimethylolpropane tetraacrylate, trimethylolethane triacrylate, pentaerythritol triacrylate, pentaerythritol tetraacrylate, dipentaerythritol tetraacrylate, dipentaerythritol pentaacrylate, dipentaerythritol Hexaacrylate, dipentaerythritol hexaacrylate ε-caprolactone adduct, pyrogallol triacrylate, propionic acid / dipentaerythritol triacrylate, propionic acid / dipentaerythritol tetraacrylate, hydroxypivalyl aldehyde-modified dimethylolpropane triacrylate, etc. Functional acrylic esters Rukoto can. Further, as the acrylic compound, a compound in which these acrylates are replaced with methacrylate, itaconate, crotonate, or maleate can also be used. One of these crosslinking agents may be used alone, or two or more thereof may be used in combination.

  Examples of the polymerization initiator used in the above polymerization reaction include azo compounds such as azobisisobutyronitrile and 1,1′-azobis (cyclohexanecarbonitrile), and organic peroxides. Of these, organic peroxides are preferred.

  As the organic peroxide, for example, methyl ethyl ketone peroxide, benzoyl peroxide, lauroyl peroxide, stearoyl peroxide, bis (4-t-butylcyclohexyl) peroxydicarbonate can be used. Further, t-hexylperoxy-2-ethylhexanoate, t-butylperoxy-2-methylcyclohexane, t-aluminoperoxybenzoate, dicumyl peroxide, t-butylperoxybenzoate, and the like can also be used. . These may be used alone or in combination of two or more.

  The content of the organic peroxide is preferably 0.05 to 10% by mass, more preferably 0.5 to 5% by mass, based on the total mass of the methyl methacrylate and the second resin precursor.

  Here, in the building member 10 of the present embodiment, the mechanism for forming the phase separation structure is not clear, but an expected mechanism will be described.

  In the manufacturing method of the present embodiment, as described above, first, methyl methacrylate 11, polymethyl methacrylate 12, the second resin precursor 13, the filler 14, the crosslinking agent 15, and the polymerization initiator are mixed, and the resin composition Prepare the product. At this time, as shown in FIG. 3A, polymethyl methacrylate 12, a second resin precursor 13, a filler 14, a cross-linking agent 15, and a polymerization initiator were dispersed in methyl methacrylate 11, which was liquid at room temperature. State.

  When the resin composition is heated in this state, as shown in FIG. 3B, the methyl methacrylate 11 is polymerized by the effect of the polymerization initiator to generate polymethyl methacrylate 16. At the same time, due to the effect of the polymerization initiator, the second resin precursor 13 is polymerized to form the second resin 17, and a part of methyl methacrylate is copolymerized with the second resin precursor 13 to form a copolymer. A coalescence 18 is also generated. Further, the methyl methacrylate 11 and the second resin precursor 13 also polymerize with the crosslinking agent 15.

  Then, as the polymerization reaction proceeds, the first resin phase 1 formed by mixing the acrylic resin formed by three-dimensionally cross-linking methyl methacrylate and polymethyl methacrylate is formed. A second resin phase 2 formed by mixing a second resin obtained by polymerizing the second resin precursor 13 and a copolymer obtained by three-dimensionally cross-linking the methyl methacrylate 11 and the second resin precursor 13. Is also formed. As a result, as shown in FIG. 3C, a phase separation structure including the first resin phase 1 and the second resin phase 2 can be obtained.

  On the other hand, when the uncured resin composition does not contain the second resin precursor 13, as shown in FIG. 4A, methyl methacrylate 11, polymethyl methacrylate 12, and filler 14 are used. , The crosslinking agent 15 and the polymerization initiator are in a dispersed state.

  When the resin composition is heated in this state, as shown in FIG. 4B, the methyl methacrylate 11 is polymerized by the effect of the polymerization initiator to generate polymethyl methacrylate 16. Further, the methyl methacrylate 11 also polymerizes with the crosslinking agent 15. Then, as the polymerization reaction proceeds, as shown in FIG. 4C, the first resin phase formed by mixing the acrylic resin formed by three-dimensionally cross-linking methyl methacrylate and polymethyl methacrylate. Only one is formed.

  In addition, the phase separation structure in the building member 10 is formed not only by the above-described micro-level phase separation mechanism, but also by the influence of the polymer constituting the second resin or the copolymer of the second resin precursor and methyl methacrylate. Could be. However, at this time, the mechanism by which the phase separation structure is formed is unknown. Therefore, even if the building member 10 of this embodiment forms a phase separation structure by another mechanism, the technical scope of this embodiment is not affected at all.

  Thus, the building member 10 of the present embodiment is formed of the first resin phase 1 formed of the first resin and the second resin different from the first resin, and is three-dimensionally formed inside the first resin phase 1. And a phase separation structure having a substantially continuous second resin phase 2. The first resin phase 1 is a light transmitting phase that transmits light, and the second resin phase 2 is a light guiding phase that transmits incident light. Since the building member 10 of the present embodiment can be formed by a single layer having one phase separation structure, it is possible to suppress an increase in thickness and to save space. Further, as described above, since the phase-separated structure is formed by mixing the resin, the building member 10 can be easily manufactured. Further, since the second resin phase 2 which is a light guiding phase is formed inside the first resin phase 1 which is a light transmitting phase, the first resin phase 1 and the second resin phase 2 are not easily separated. Therefore, the architectural member 10 can exhibit high designability over a long period of time.

[Artificial marble and building material integrated lighting equipment]
Next, the artificial marble and building material-integrated lighting device according to the present embodiment will be described in detail with reference to the drawings.

  The artificial marble of the present embodiment is made of the above-described building member 10. As described above, the building member 10 can express colors, patterns, and textures by selecting various fillers. Further, in the building member 10, two or more resins can be phase-separated at a visible level using a resin phase separation technique. Therefore, in the building member 10, a three-dimensional pattern derived from the shapes of the first resin phase 1 and the second resin phase 2 that have undergone phase separation can be provided. As a result, the architectural member 10 itself is provided with excellent design even without light incident on the second resin phase 2, and the architectural member 10 itself can be used as artificial marble.

  The artificial marble of the present embodiment is excellent in strength, surface hardness, designability, and water resistance. Therefore, it can be suitably used for applications requiring a good appearance, for example, kitchen counters, vanities, bathtubs, floor pans (waterproof pans), water-washing members such as washbasins, and the like.

  As shown in FIG. 5A, the building material-integrated lighting device 100 according to the present embodiment includes the above-described building member 10 and a light source 20 that emits light into a light guide phase of the building member 10.

  As shown in FIG. 5A, when light is incident from the light incident part 2 a using the light source 20, the incident light is reflected at the interface between the first resin phase 1 and the second resin phase 2. Then, by repeating this reflection, the incident light propagates toward the end opposite to the light incident portion 2a. At this time, part of the propagating light is emitted from the interface between the first resin phase 1 and the second resin phase 2, transmitted through the first resin phase 1, and emitted from the surface of the building member 10. .

  As described above, since the building material-integrated lighting device 100 can emit light along the pattern of the second resin phase 2 from the inside of the building member 10, it can be a lighting device having a high design quality. Further, since the building member 10 is formed of the resin-made phase separation structure as described above, it can be formed into an arbitrary shape such as a flat plate shape. Therefore, space saving of the building material integrated lighting fixture 100 can be achieved. In addition, since the light is emitted from the inside of the building member 10, the appearance can be made such that a deep part of the building member 10 emerges, and a three-dimensional effect can be effectively expressed.

  Also, as shown in FIG. 5B, the building material-integrated lighting device 100A of the present embodiment is provided on the back surface 10a of the phase separation structure, and shields the emission from the first resin phase 1 and reflects it on the front surface 10b. An architectural member 10A provided with a reflective layer 3 to be used may be used. Thereby, it is possible to suppress the emission from the back surface 10a of the building member 10A and efficiently radiate it from the front surface 10b.

  The light source 20 is not particularly limited as long as light can enter the inside of the second resin phase 2 from the light incident portion 2a of the second resin phase 2 which is a light guide phase. As the light source 20, for example, a point light source such as a light emitting diode (LED) or a linear light source such as a fluorescent lamp can be used.

  In the building material-integrated lighting device 100, the light source 20 is preferably located at an end of the building member 10. As shown in FIGS. 5A and 5B, when the building member 10 has a flat plate shape, the light source 20 is provided on the side surface 10 c of the building member 10, so that the front surface 10 b, the back surface 10 a, and Light is emitted from the side surface 10d opposite to the side surface 10c. Therefore, it is possible to efficiently irradiate light while saving the space of the building material integrated lighting fixture 100.

  FIG. 6 illustrates an application example of the building material-integrated lighting device 100, for example, an example in which the building material-integrated lighting device 100 is applied to a vanity stand. In the vanity table of FIG. 6, the building material-integrated lighting device 100 is disposed on both the left and right sides of the mirror 200 located on the front. When the light source 20 of the building material-integrated lighting device 100 is not turned on, since the artificial marble including the building member 10 is provided on both sides of the mirror 200, the sense of quality of the vanity table can be enhanced. . In addition, when the light source 20 of the building material-integrated lighting device 100 is turned on, light is emitted from both sides of the mirror 200, so that the face and the upper body can be efficiently moved regardless of the height of the user. It becomes possible to illuminate.

  When the building material-integrated lighting device 100 is applied to a bathroom vanity, the position of the light source 20 is not particularly limited. For example, as shown in FIG. 6, the light source 20 can be provided on the upper part 10e of the building member 10. Thereby, it becomes possible to achieve space saving of the building material integrated lighting fixture 100.

  Hereinafter, the present embodiment will be described in more detail with reference to examples, but the present embodiment is not limited to these examples.

[Production of resin molded body]
64 parts by mass of methyl methacrylate, 16 parts by mass of polymethyl methacrylate, 20 parts by mass of cyclohexyl methacrylate as a second resin precursor, 1.0 part by mass of a crosslinking agent, and 0.2 parts by mass of a polymerization initiator The acrylic resin composition was prepared by mixing at a ratio. The polymethyl methacrylate (PMMA) used was obtained by bulk polymerization of methyl methacrylate (MMA) so that the weight average molecular weight became 100,000. As cyclohexyl methacrylate, Wako Pure Chemical Industries, Ltd. was used. As a crosslinking agent, trimethylolpropane trimethacrylate was used. The polymerization initiator used was Perbutyl (registered trademark) Z (t-butylperoxybenzoate) manufactured by NOF Corporation.

  Then, the acrylic resin composition was cured by heating at 70 ° C. for 2 hours to obtain a resin molded body of this example. FIG. 7 shows the obtained resin molded body.

[Appearance evaluation]
As shown in FIG. 7, the resin molded body obtained as described above forms a bicontinuous phase-separated structure by the first resin phase 1 and the second resin phase 2 to form a three-dimensional network-like pattern. It can be seen that is formed. It can also be seen that the size of the light guide phase composed of the second resin phase 2 is 1 mm or more. Further, when a light source was applied from the side surface of the obtained resin molded body and the surface of the resin molded body was visually observed, it was confirmed that light was emitted from the second resin phase 2.

  As described above, the contents of the present embodiment have been described along with examples, but the present embodiment is not limited to these descriptions, and it is obvious to those skilled in the art that various modifications and improvements are possible. is there.

DESCRIPTION OF SYMBOLS 1 1st resin phase 2 2nd resin phase 10, 10A Building member 14 Filler 17 2nd resin 20 Light source 100, 100A Building material integrated lighting fixture

Claims (10)

It has a first resin phase formed of a first resin and a second resin phase formed of a second resin different from the first resin and three-dimensionally continuous inside the first resin phase. Equipped with a phase separation structure,
Wherein the first resin phase is light-transmitting phase to transmit light, the second resin phase Ri light phase der propagating incident light,
Building element width of the second resin phase which is characterized in der Rukoto than 0.5 mm.   The building member according to claim 1, wherein the second resin has a higher refractive index than the first resin.   The building member according to claim 1, wherein the first resin phase includes an acrylic phase derived from methyl methacrylate.   The building member according to any one of claims 1 to 3, wherein the first resin phase includes polymethyl methacrylate.   The building member according to any one of claims 1 to 4, wherein the second resin is made of a material that is phase-separated from the first resin.   The building member according to claim 5, wherein the second resin includes at least one selected from the group consisting of a (meth) acrylate monomer, a (meth) acrylate oligomer, and a (meth) acrylate polymer.   The building member according to any one of claims 1 to 6, wherein at least one of the first resin phase and the second resin phase contains a filler.   An artificial marble comprising the building member according to any one of claims 1 to 7. The building member according to any one of claims 1 to 7,
A light source for entering light into the light guide phase of the building member,
A lighting device integrated with a building material, comprising:   The lighting device according to claim 9, wherein the light source is located at an end of the building member.