JPH07186316A - Resin lightweight laminate and its manufacture - Google Patents

Abstract

PURPOSE:To obtain a laminate wherein lightweight is achieved and a resilience cushioning property is provided, a warp is free from occurrence, and strength is improved by a simple method wherein a styrene resin extrusion-based low foamed board is integrated by fusion welding onto front and rear surfaces of a molded board simultaneously with molding of the molded board from styrene resin foaming particles. CONSTITUTION:Many through holes (h) are formed in styrene resin extruded low foamed boards 1, 2 as each layer board for two layers. Then, a space being a hole between the two layers is formed. After setting them in a molding tool, styrene resin-based foaming particles are filled by supply in the space between the two layers. Thereafter, steam is supplied through the through hole (h), and the styrene resin-based foaming particles are welded by fusion to each other. A molded board 3 is formed in beads, and besides two styrene resin extrusion-based foamed boards 1, 2 are integrated by fusion with the front and rear surfaces of the molded board 3.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a lightweight resin laminate used for construction materials and the like and a method for producing the same.

[0002]

Conventionally, veneer plywood and other plywood have been widely used as building materials such as flooring and ceiling materials, but it is necessary to make them more elastic as plywood. A device for forming a sponge layer or a styrofoam layer between veneer plates has also been proposed (Japanese Utility Model Laid-Open No. 58-191216), but even if it is lightweight and elastic, it is not possible to prevent warpage peculiar to plywood. , Was not stable in strength.

In view of the above, it is an object of the present invention to provide, by a simple method, a laminated plate which is light in weight and has elasticity cushioning property, and which is not warped and has improved strength.

[0004]

As a constitution of a resin lightweight laminated board according to the present invention which can achieve the above object, a styrene resin extruded low foamed board is formed at the same time as molding of a molded board from styrene resin foamed particles. It is characterized by being fused and integrated on the front and back. In addition, as a manufacturing method for easily obtaining the above laminated plate, a large number of through holes are formed in each two-layer plate made of a styrene resin extruded low foam plate,
The space between the two layers is formed as a mold cavity and set in a molding die. The foamed particles of styrene resin are filled in the space and the steam is supplied from the through holes of the two layers to fuse the foamed particles to each other. It is characterized in that two layers of extruded low-foaming plates are fused and integrated as the front and back of the molded plate at the same time when the molded plate is molded by molding.

[0005]

In the resin lightweight laminate according to the present invention, the styrene resin extruded low foam plate is fused and integrated on the front and back of the molded plate simultaneously with the molding of the molded plate from the styrene resin expanded particles. Regardless of the structure, the joint surfaces can be fused together and integrated as a whole, so that a very strong joint can be achieved.

Further, the strength without warpage is much enhanced as compared with the polystyrene foam alone.
In addition, it is possible to achieve the effects of weight reduction, cushioning, soundproofing, moistureproofing, and heat insulation. Furthermore, a styrene resin extruded low foam plate can be formed to have a wood grain appearance.

Further, according to the above-mentioned method for producing a laminated plate, in order to integrate the extruded low-foam plate on the front and back of the molded plate made of expanded particles, a large number of through holes are formed in the extruded low-foam plate on the front and back sides in advance. The two layers of the extruded low-foam plate are set at intervals so as to form a mold cavity, and the foam particles filled and supplied in the space are foam-molded by a steam supplied through the through-holes, so-called beads. It is possible to provide a laminate having the extruded low-foamed plate on the front and back after molding by molding and forming the molded plate and the extruded low-foamed plate by fusion bonding without using an adhesive during the molding.

[0008]

Embodiments Next, embodiments of the present invention will be illustrated with reference to the drawings. Reference numerals 1 and 2 are extruded low foam plates of styrene resin such as polystyrene, and are foam plates in which a large number of extruded foamed strand-shaped strips are fused to each other. Reference numeral 3 is a molded plate molded from expanded particles of styrene resin such as polystyrene, and the extruded low foam plates 1 and 2 are fused and integrated with the surface of the molded plate 3 at the time of molding.

A method of manufacturing the laminated plate of the present invention will be described. A large number of through holes h are formed in each of the extruded low-foaming plates 1 and 2 which will be the two laminated plates. And above 2
After forming a space that will be a mold cavity between layers and setting it in the mold,
The expanded polystyrene particles are filled and supplied in the space between the two layers,
Steam is supplied through the through holes h to fuse the foamed particles to each other to form the molded plate 3 by so-called bead molding, and at the same time, the two layers of the extruded low foam plates 1 and 2 are fused and integrated on the front and back of the molded plate 3. You can

When the application is, for example, a concrete construction panel, the size is about 1000 × 2000 mm, and when it is small for other applications, it is cut and used. In addition, a part of the expanded polystyrene particles may enter into the through hole h during fusion bonding. Specific examples of the present invention will be given below.

Extruded low-foaming boards 1 and 2 (trademark: Trademark:
Sekisui Shinki Sekisui Plastics Co., Ltd.) 4.0 mm
Through holes h having a diameter of about 1 mm are formed at intervals of 30 mm in a material having a thickness of 0.41 and a specific gravity of 0.41. The extruded low foam plates 1 and 2 are set in a molding die, and a plate gap of two layers is used as a mold cavity, and polystyrene foam particles (trademark: Eslen beads-Sekisui Plastics Co., Ltd.) are supplied into the mold cavity. To fill.

Next, steam is passed through the through holes h to fuse the polystyrene expanded particles to each other to form the molded plate 3 (expansion ratio 7).
2) is formed into a thickness of 5 mm, and at the same time, the extruded low foam plates 1 and 2 are fused and integrated on the front and back of the forming plate 3. The weight in this case was 4000 g / m ² . When the total density of the entire laminated plate was examined from the above specific example, it was found to be lightweight as follows. Polystyrene extruded low foam plate (4.0 mm thickness, density 410 kg / m ³ ) × 2 = 8.0 mm thickness Molded plate made of polystyrene foam particles (5.0 mm thickness, density 143 kg / m ³ ) × 1 = 5.0 mm thickness TOTAL Density = 307kg / m ³

[0013]

INDUSTRIAL APPLICABILITY As described above, the laminated plate according to the present invention is suitable for building materials such as flooring materials, wall materials, and ceiling materials, particularly as interior panels and concrete construction panels for concrete buildings. Since the foamed plate is fused and strongly bonded to the front and back of the synthetic plate simultaneously with the molding of the molded plate made of expanded styrene resin particles, the following effects can be obtained. It has light weight and cushioning properties. Simultaneously with the molding, the molded plate made of expanded particles and the extruded low-foamed plates on the front and back that are fusion-bonded to each other increase the strength. The laminated plate does not warp. It has a high soundproofing effect, no fear of moisture absorption, and a high heat insulating effect. The front and back surfaces can be formed in a wood grain fashion, and natural wood resource conservation can be realized. Easy to cut. Since it is a laminated plate of the same type of resin and does not have an adhesive, it is easy to recycle after collecting it after use.

Further, in the present invention, as a method for producing a laminated board, a large number of through holes are formed in each of the two layers of extruded low-foamed styrene resin boards, and the spaces between these two layers are used as mold cavities. After being formed as a mold and set in a molding die, foamed particles made of styrene resin are filled in this space, and steam is supplied from two layers of through holes to fuse the foamed particles to each other to form a molding plate and simultaneously Since the extruded low-foam plate is fused and integrated with the above, it is possible to efficiently provide a unique laminated plate having the above-mentioned effect by the three layers having the extruded low-foam plate on the front and back and the molded plate made of expanded particles in the center.

[Brief description of drawings]

FIG. 1 is a cross-sectional view of a laminated plate.

FIG. 2 is a perspective view of front and back extruded low foam plates.

[Explanation of symbols]

 1, 2 Extruded low foam plate h Through hole 3 Molded plate made of expanded particles

Claims (2)

[Claims] 1. A lightweight resin laminate comprising a styrene resin extruded low-foaming plate, which is fused and integrated on the front and back sides of the molded plate simultaneously with the molding of the molded plate from the styrene resin foamed particles. 2. A plurality of through-holes are formed in each of the two layers of styrene resin extruded low-foam plate, and the two layers are set in a molding die with a gap to form a mold cavity between them. The space is filled with foamed particles of styrene resin, and steam is supplied from two layers of through holes to fuse the foamed particles to each other to form a molded plate, and at the same time, two layers of extruded low-foamed plate are used as front and back surfaces of the molded plate. A method for producing a resin lightweight laminate, which is characterized in that fusion and integration are performed.