JPH0557737A - Production of thin synthetic resin plate - Google Patents

Abstract

PURPOSE:To obtain a thin plate with a thickness of 6mm or less being a limit in the present situation having uniform thickness and almost no thickness error. CONSTITUTION:Several kinds of molding materials 1 based on a fluid synthetic resin are mixed to be sprayed to the interior of a rotary cylinder 2 under rotation or injected in said cylinder 2 to be applied to the inner wall surface of the cylinder 2 and cured until it becomes a gel state while the rotary cylinder 2 is rotated. Thereafter, the molding materials 1 are taken out of the rotary cylinder 2 and made flat on a horizontal table to be perfectly cured to produce a thin plate.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing a synthetic resin thin plate used as a building material such as wall materials, floor materials, and ceiling materials.

[0002]

2. Description of the Related Art As a method of manufacturing a thin plate used for wall materials, floor materials, ceiling materials, etc. using a synthetic resin, a compound resin is put in a mold and then heated and pressed. Press molding, extrusion molding (T-die method), in which heated resin is extruded from a die with a narrow gap to form a block, and this is further stretched by a roll to make it thinner, A method such as injection molding in which a resin is injected and then heated to be cured is used.

[0003]

However, in press molding, a mold with high precision and excellent balance is required, but it is still very difficult to achieve 100% balance (for example, If an attempt is made to manufacture a thin plate with a standard size of 4 m × 500 mm × 3 mm, an error of at least 0.5 mm will occur). However, if these thin plates are joined together, a step will occur at the joint, and a grinding step will be required and an extra It takes time and effort. Moreover, the mold is very expensive, and the cost is greatly affected together with the cost of the grinding process.

Further, press molding can produce only a single-color thin plate, and it is impossible to produce a thin plate having various patterns such as a flow pattern.

Further, the molding material (raw material) currently used for press molding is a compound-like material represented by the terms BMC, SMC, and glass fiber and low shrinkage material are indispensable. However, this may cause the product to lose its transparency and become inferior in texture.

[0006] In extrusion molding, since the thickness is determined by several stages of rolls, a thickness error is unavoidable and a post-polishing step is required, which is time-consuming, and a resin and an inorganic filler are mixed, Since this is extruded to produce a thin plate, inorganic substances appear on the surface of the product during production, and the glossiness due to post-polishing is inferior to the product produced by injection molding with a resin layer on the surface Will be.

In injection molding, the mold used for casting is mainly the FRP type, which is roughly classified into an open type and a closed type. However, in the closed type, the injection port is narrow when a thin plate of 6 mm or less is produced. Therefore, it is difficult to inject the resin, and even if it is attempted to cast the resin in small amounts, it takes time and labor, resulting in poor productivity. On the other hand, the open type is easy to cast, but the balance of the mold is very difficult and a thickness error of 1 to 2 mm or more occurs, and secondary processing such as cutting and leveling later is required, which is troublesome. In addition to this, there was a problem in terms of cost.

The present invention is intended to solve the above problems of each molding method, and provides a thin plate having a uniform thickness easily and inexpensively by completing the invention described below. It was possible to achieve the purpose.

[0009]

According to the present invention, several kinds of molding materials mainly composed of a flowable synthetic resin are mixed and sprayed or injected into a rotating rotary cylinder (2). Then, the rotary cylinder (2) is attached to the inner wall surface of the rotary cylinder (2) to have an arbitrary thickness.
After the molding material (1) is cured while being rotated until it becomes a gel state, the molding material (1) is taken out from the rotary cylinder (2) and completely cured to obtain a composition having a uniform thickness. A resin thin plate is to be produced, or a molding material is sprayed or injected into the rotary cylinder (2) and adhered to the inner wall surface of the rotary cylinder (2) to have an arbitrary thickness, and then gelled. Another object of the present invention is to manufacture a molding material thin plate having a uniform thickness as a multilayer by spraying or injecting another kind of molding material onto the surface of the molding material so that the molding material adheres to an arbitrary thickness.

[0010]

[Operation] By spraying or injecting a fluid molding material into the rotating rotating cylinder, the molding material is attached to the inner wall surface of the rotating cylinder by centrifugal force and is naturally leveled to have a uniform thickness. can do.

[0011]

EXAMPLES As one example of the present invention, a method for manufacturing a granite-like artificial marble thin plate will be described below.

First, a molding material for a top coat layer containing 98% of an unsaturated polyester resin which is a thermosetting resin and 2% of a curing agent as a synthetic resin having fluidity is well mixed and rotated. The thickness is 0.
It is sprayed so as to be 3 mm or more and 0.6 mm or less. The sprayed molding material for the top coat layer is leveled by the centrifugal force generated by the rotation of the rotary cylinder to have a uniform thickness and is stuck to the inner wall surface of the rotary cylinder.

Next, when the reaction of the molding material progresses and loses fluidity and becomes a gel state, a separately prepared unsaturated polyester resin 60%, inorganic filler 35%, crushed particles 4
%, And 1% of a curing agent, a molding material for a granite pattern is poured into the surface of the gelled molding material for the top coat layer to form a layer. At this time, a thin plate having a total thickness of about 2 mm to 6 mm is used.

The molding material leveled by the centrifugal force caused by the rotation of the rotary cylinder and stuck to the inner wall surface of the rotary cylinder with a uniform thickness is maintained until the gel state is maintained while the rotary cylinder is rotated.

At this time, the bubbles that have entered during stirring and mixing of the molding material are discharged into the air from the inside of the molding material toward the center of the rotation cylinder due to the difference in specific gravity with the molding material and the centrifugal force of the rotation cylinder, and all are removed. Will be done.

Thereafter, the molding material hardened to such an extent that it can be taken out from the rotary cylinder is cut at one place so that it can be made flat, and taken out from the rotary cylinder and placed on a horizontal heat treatment table. .. The molding material that has been completely cured on the heat treatment table is a granite-like artificial marble thin plate having a uniform thickness.

As another embodiment, a method of manufacturing a marble-like artificial marble thin plate will be described.

First, similar to the molding material for the top coat layer used in the method for producing the granite-like artificial marble thin plate, 98% of unsaturated polyester resin and 2% of curing agent are used.
The molding material for a top coat layer consisting of is mixed well and sprayed into a rotating rotating cylinder so that the thickness is 0.3 mm or more and 0.6 mm or less.

When the sprayed molding material is leveled to a uniform thickness and the reaction progresses and loses fluidity and becomes a gel state, a gel coat of two types of separately prepared molding materials for pattern formation is formed. It is poured at the same time so as to form a layer on the surface of the layered molding material to obtain a flow-patterned thin plate having a total thickness of about 2 mm to 6 mm.
The molding material for pattern formation at this time was a white marble pattern molding material composed of 60% unsaturated polyester resin, 36% inorganic filler, 2% white pigment, and 2% curing agent, and 61% unsaturated polyester resin, A green marble pattern molding material composed of 36.5% of inorganic filler, 0.5% of green pigment, and 2% of curing agent. These are used to form a flow pattern by using a jig as shown in FIG. Inject. The pattern thus obtained is of a so-called onyx tone in which green is mainly contained and white flow is mixed.

Thereafter, similar to the method for producing the granite-like artificial marble thin plate, the molding material is taken out from the rotary cylinder and cured on a heat treatment table to obtain a thin plate having a marbled pattern and a uniform thickness. ..

Also, various flow patterns can be applied by changing various jigs used for applying the pattern.

Further, in the present invention, it goes without saying that molding can be performed without the top coat layer, and there is no problem even if unevenness is provided on the inner wall surface of the rotary cylinder and a pattern is formed on the surface of the thin plate.

[0023]

As described above, according to the present invention, it is possible to manufacture a thin plate having a uniform thickness with almost no thickness error as compared with the conventional technique, and a thin plate having a thickness of 6 mm or less, which is the limit at present. It is possible to say that this is a manufacturing method which is extremely excellent in productivity because the manufacturing method is simple.

Further, since a grinding process or a polishing process is not required as a post-process after forming the thin plate, it is a manufacturing method which is excellent in workability and economical efficiency without extra labor and cost.

Further, it is possible to apply various patterns and it can be used as a product as it is, but by adhering and reinforcing it with a poly plywood, a non-combustible material plate, etc., a product suitable for various purposes can be obtained. it can.

[Brief description of drawings]

FIG. 1 is a schematic view showing a rotary cylinder used in the present invention.

FIG. 2 is an explanatory view showing a process of the present invention.

FIG. 3 is a perspective view showing a jig used for applying a pattern in the present invention.

[Explanation of symbols]

 1 ... Molding material (raw material) 2 ... Rotating cylinder 3 ... Pattern forming jig

Claims (2)

[Claims] 1. Mixing several kinds of molding materials mainly composed of a fluid synthetic resin, and spraying or injecting this into a rotating rotary cylinder to obtain an arbitrary thickness on the inner wall surface of the rotary cylinder. A method for producing a synthetic resin thin plate, characterized in that the molding material is adhered in such a manner that it is cured until the molding material is in a gel state while the rotation cylinder is rotated, and then the molding material is taken out of the rotation cylinder and completely cured. 2. The surface of the gelled molding material is further sprayed or injected with another kind of molding material so that the molding material adheres to a desired thickness to form a multilayer.
The method for producing a synthetic resin thin plate according to 1.