JPH04209771A - Porous material and its production - Google Patents

Abstract

PURPOSE:To precisely provide a porous material having fine openings on the surface and further having a number of fine pores not reaching the back surface by sieving the mixture of a fine powdery material with a liquid reactive resin, and subsequently heating and press-molding the sieved fallen powdery material alone having a specific particle diameter. CONSTITUTION:A fine powdery material having a particle diameter of <=0.3 mm is preliminary mixed with a reactive resin in a true volume ratio of 1:1 to 20:1, the reactive resin being liquid when mixed. The mixture is applied to a sieve whose openings have a mesh size of from the diameter of the fine powdery material to 5 mm. The fallen powdery material is spread on a mold and subsequently heated and press-molded into the objective porous material. The porous material thus produced exhibits substantially no slipperiness on wetting with water and is slightly stained. The porous material can thereby be effectively utilized as a floor material for bath rooms, cooking rooms, lavatories, entrances, verandas, pool sides, shower rooms, etc. The porous material is further suitable as a building material such as a moisture-adsorbing and desorbing wall material or a sound-proof material.

Description

[Detailed description of the invention] [Industrial application field]

The present invention relates to a porous material suitable for various building materials such as flooring materials, moisture absorbing/releasing wall materials, soundproofing materials, etc. used in places easily exposed to water, and a method for manufacturing the same.

[Conventional technology]

Places that are prone to getting wet, such as bathrooms, galleys, toilets, entrances, balconies, poolside, shower rooms, etc.
In order to prevent slipping due to water, a porous floor material is used, for example, as seen in Japanese Utility Model Publication No. 15308/1983. This porous floor material is made by coating the surface of aggregate such as sand with a particle size of 0.3 mm or more with thermosetting resin, and connecting and solidifying the aggregate at the contact area with this thermosetting resin. Continuous water permeable holes are formed between the aggregates, and these water permeable holes allow water to permeate from the surface to the back surface, thereby preventing slippage when wet.

[Problem to be solved by the invention]

However, in the above-mentioned porous floor material, the diameter of the water permeable pores is large because the aggregates are simply connected and solidified at the contact portions to form gaps between the aggregates. Therefore, there is a problem in that solid foreign matter enters the water permeation hole together with water, causing clogging and staining. The present invention aims to provide the production of a novel porous material that can solve the problems of the prior art.

[Means to solve the problem]

In order to achieve such an object, the present invention has been developed by adding a reactive resin that is liquid at the time of mixing to fine powder particles having a particle size of 0.3 m+n or less in a true volume ratio in the range of 1:1 to 20:1. The resulting mixture is passed through a sieve with a mesh diameter of not less than the particle size of the fine powder and 5 mm or less, and the powder that falls from the sieve is spread on a mold and pressurized and heated. The gist of this paper is a method for producing porous materials.

[For production]

Fine granules with a predetermined particle size and a predetermined amount of reactive resin are mixed with the fine granules, and the resulting mixture is passed through a sieve with a predetermined diameter to form a powder with a uniform diameter of a predetermined diameter or less. Get a body. Then, by dropping this powder onto a mold and spreading it over the mold, and applying uniform pressure, an uncured molded product with fine voids formed between the fine powder particles can be molded. Since the uncured molded body is cured, it is possible to mold a porous material that has a smooth surface with no uneven openings during molding, and has many pores with minute openings formed on the surface. When the resulting porous material is used as a flooring material in wet areas such as bathrooms, the surface is smooth, so if you stand barefoot on it, the soles of your feet will touch the floor smoothly. In addition to the close contact, even if the floor surface is wet, the water pressed by the soles of the feet escapes into the pores through the openings, so there is no water film between the soles of the feet and the floor surface. Note that since the pores do not reach the back surface, water that has entered the pores does not permeate to the back surface side. Furthermore, since the openings are minute, dirt and the like are prevented from entering the pores through the openings.

【Example】

The present invention will be explained in detail below with reference to examples thereof. The method for producing a porous material according to the present invention is carried out in the following order. ■ A reactive resin that is liquid at room temperature is added to a fine powder having a particle size of 0.3 mm (usually an average value) or less in a true volume ratio of 1:1 to 20:1, preferably lo: 3 to 20:1
Add and mix in the following proportions. In addition, it is preferable that the mixture obtained by mixing is uniformly mixed so that the dispersion of the amount of resin from the average value is 10% or less, preferably 5% or less based on the resin. The mixing method includes mixing with various blenders (e.g., Super Mixer, Eirich Mixer (manufactured by Eirich Mixer), etc.), and further using a dispersing machine (e.g., Turbulizer, manufactured by Hosokawa Micron, Dyno Mill, manufactured by Bachoten, etc.). A method using a device that sprays liquid resin onto fine powder and stirs it [for example, a Shugie mixer manufactured by Sugie, various air flow mixers, a Sutter mixer manufactured by Acme, a flow shed mixer manufactured by Kouken Powtex, etc.] etc. Examples of the fine powder include kaolin, clay, silica sand, natural mineral fibers, crushed natural stone powder, mica, glass milled fibers, alumina staple fibers, potassium titanate staple fibers, carbon staple fibers, and whiskers. Any of these can be used alone or in combination. The optimum dimensions and particle diameter of the fine powder vary depending on the use of the porous material, etc., but the particle size is 300- or less (please note that it is preferable that the particle sizes are uniform, but an average of 300- or less is also acceptable). ) is used. By adjusting the fiber thickness, particle size, and shape of the fine powder and the viscosity of the thermosetting resin, it is possible to adjust the diameter of the surface opening. In addition, reactive resins that are liquid at room temperature, such as
Unsaturated polyester resins, epoxy resins, phenolic resins, furan resins, imide resins, acrylic resins (including room temperature curing reactive resins that do not necessarily require heating)
etc. ■ Pass the obtained mixture through a sieve (the shape is not particularly limited, such as a mesh or one with many holes) having a mesh diameter of 5 mm or less, which is larger than fine powder. The powder that has fallen from the mold is spread over the mold. Note that when the mixture is passed through a sieve with a mesh diameter exceeding 5 mm, it falls in lumps, and large openings appear on the surface of the molded product after shaping due to the voids between the lump particles. ■ After shaping, pressurize and heat, or directly press and heat without shaping to obtain the desired porous material. Shaping is performed by a method such as spreading the powder on a mold and then scraping it with a doctor knife or the like. Pressurization and heating may be performed at the same time, or heating may be performed after pressurizing and molding into a desired shape. Also, prior to pressurization, the upper part of the powder is elastically deformed and/or
Alternatively, it is preferable to cover with a plastically deformable cushion sheet and pressurize the powder through this cushion sheet. That is, unless a cushion sheet is used, uniform molding may not be possible, especially if the mold has undulations or warps. Examples of cushion sheets include, but are not limited to, rubber sheets, foams, felts, nonwoven fabrics, clay-like pastes, and composites thereof. (Example 1) In advance, alumina fiber (300 mesh) 2
000 parts by weight of epoxy resin (a mixture of Epikote 828 manufactured by Yuka Shell Co., Ltd. and an acid anhydride curing agent in equal amounts of epoxy) was added to 2000 parts by weight (bulk volume ratio 1:0.25) and mixed. The resulting mixture was passed through a 3 mm sieve, dropped as a powder, uniformly spread on a mold, ground with a doctor knife, and heated and cured in a press at 80° C. to obtain a plate-shaped molded product. (Example 2) 1200 parts by weight of vinyl ester resin (manufactured by U-Pica Japan) was added and mixed in advance to 3500 parts by weight of mica (100 mesh pass) (bulk volume ratio 1:0.27), and the resulting mixture was mixed. The powder was passed through a Lun sieve, dropped as a powder, uniformly spread on a mold, ground with a doctor knife, pressed with a press, and heated and cured at 100°C to obtain a plate-shaped molded product. (Example 3) 1500 parts by weight of unsaturated polyester resin (bulk volume ratio 1:0.25) was added and mixed in advance to 6000 parts by weight of quartz powder (200 mesh passes), and the resulting mixture was mixed with 4M
The mixture was passed through a sieve, dropped as a powder, uniformly spread on a mold, pressurized (50 kg/cnf), and heated and cured at 80°C to obtain a plate-shaped molded product. (Comparative Example 1) A molded body was obtained in the same manner as in Example 1 except that a 15 mm sieve was used. (Comparative Example 2) A molded body was obtained in the same manner as in Example 1 except that a 9 mm sieve was used. (Conventional Example) As described in Utility Model Publication No. 15308/1983, 0
．． 5 parts by weight of sand with a particle size of 3 mm or more is mixed with 1 part by weight of unsaturated polyester resin, the surface of the sand is coated with the resin, and this is placed in a mold and heated and cured at 80'C to form a plate-shaped molded product. (Water permeable resin concrete material) was obtained. Examples 1 and 2, Comparative Example 1. 2. Pore diameter, pore volume, stain resistance, and slip resistance of the molded body obtained in the conventional example and the glass filter made by Ise Chemicals (microporous glass 1 mm x 100 mm x l 00 mn+ with a pore diameter of 0.3 il T11) as a reference example. The results are shown in Table 1. The aperture diameter is measured by mercury porosimetry, and the evaluation is ◎ if the volume fraction of the pore volume including the aperture to the total pore volume is 101 m or more and less than 10%;
10. If cm or more is 10% or more and less than 30%, mark it as ○.
Those with 30% or more of 101n11 or more are marked with an x. Regarding pore volume, those in which the ratio of the total pore volume to the porous material is 2% or more are marked with ◎, and those with a ratio of less than 2% are marked with ×.
It was shown in Contamination resistance was tested by dispersing talcum powder (10μ or less) in water (0.2g/cc) and spraying this liquid 50a on a test piece 100mm x 100+nm at appropriate times.The evaluation was based on whether talcum powder remained on the surface. , items that can be washed away later are marked ◎, and items where talcum powder has leaked out from the back side or caused clogging are marked with As shown in Figure 1, a piece of artificial leather (50 mm
x 30 mm) 2. Using a load of 2 kg, change the inclination of the porous material (molded body) 1 and measure the angle θ at which the artificial leather piece begins to slide, and calculate the coefficient of friction (tan θ). A coefficient of 0.6 or more is indicated by ◎, and a coefficient less than 0.6 is indicated by ×. Table 1 As shown in Table 1, Example 1. 2 were all good, but Comparative Examples 1 and 2 had poor evaluations of opening diameter, pore volume, and stain resistance, and conventional and reference examples had poor evaluations.
There was a problem with stain resistance.

【Effect of the invention】

Since the method for producing a porous material according to the present invention is configured as described above, the surface is substantially smooth, has fine openings on the surface, and has many pores inside that do not reach the back surface. Porous materials can be obtained with high precision. The resulting porous material is resistant to slipping when wet and resistant to staining. Therefore, it can be effectively used as a flooring material in bathrooms, cooking rooms, toilets, entrances, balconies, poolsides, shower rooms, etc. In addition, since the surface has pores, it is suitable not only for flooring materials but also for various building materials such as moisture-absorbing wall materials and soundproofing materials.

[Brief explanation of the drawing]

FIG. 1 is an explanatory diagram illustrating a slip resistance test. 1...Porous material Patent applicant: Sekisui Chemical Co., Ltd. Figure 1

Claims (1)

[Claims] (1) A reactive resin that is liquid at the time of mixing into fine powder with a particle size of 0.3 mm or less in a true volume ratio of 1:1 to 20:
1, the resulting mixture is passed through a sieve with a mesh diameter of at least the particle size of the fine powder and 5 mm or less, and the powder that falls from the sieve is spread on a mold and molded under pressure and heat. A method for producing a porous material, characterized by: