JPH09254156A - Building board - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a building board having good surface smoothness. SOLUTION: A building board A is obtained by molding a molding material formed by compounding a resin waste material ground product obtained by grinding a resin waste material based on a thermosetting resin such as an artificial marble waste material or an FRP waste material with an unsaturated polyester resin. An inorg. filler with an average particle size of 2-300μm is compounded with the molding material in an amt. of 50-200 pts.wt. per 100 pts.wt. of the unsaturated polyester resin. By compounding the inorg. filler having this average particle size, the flowability of the molding material can be improved and this molding material is molded in such a state that the surface thereof is smoothly leveled to make it possible to obtain the building board A.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a building board containing resin waste material such as artificial marble waste material and FRP waste material.

[0002]

2. Description of the Related Art As a method of reusing a resin waste material containing a thermosetting resin as a main component such as an artificial marble waste material or an FRP waste material, the resin waste material is crushed and added to and mixed with an unsaturated polyester resin as a filler. Prepare the molding material,
By casting this molding material into a molding die and molding it, a method for manufacturing building boards such as decorative boards and reinforcing boards is
It has been conventionally provided in Japanese Patent Laid-Open No. 5-309753.

[0003]

However, when mixing a resin waste material crushed product obtained by crushing a resin waste material with an unsaturated polyester resin, the dispersion of the resin waste material crushed product in the unsaturated polyester resin is poor and a molding material is molded. Poor fluidity when poured into a mold for molding. For this reason, the surface of the building board obtained by molding is poor in smoothness, which is a problem particularly when the building board is used as a surface decorative board.

The present invention has been made in view of the above points, and an object of the present invention is to provide a building board having good smoothness.

[0005]

The construction board according to the present invention is made of unsaturated polyester resin, artificial marble waste material and FRP.
A building board obtained by molding a molding material containing a crushed resin waste material obtained by crushing a resin waste material containing a thermosetting resin as a main component, such as waste material, wherein the unsaturated polyester resin 100 is used as the molding material. Average particle size is 2 to 30 parts by weight
It is characterized in that 50 to 200 parts by weight of an inorganic filler of 0 μm is mixed.

According to a second aspect of the present invention, a crushed resin waste material having a particle size of 5 mm or less is used, and 50 to 1 crushed resin waste material is used for 100 parts by weight of the unsaturated polyester resin.
It is characterized by being mixed in an amount of 00 parts by weight.
The invention according to claim 3 is characterized in that a colored gel coat layer is provided on the surface.

[0007]

Embodiments of the present invention will be described below. As the resin waste material, waste material of artificial marble containing unsaturated polyester resin as a main component, waste material of FRP containing unsaturated polyester resin and glass fiber as a main component, and hardened material containing a thermosetting resin as a main component. Is used, and any waste material of a cured product containing a thermosetting resin as a main component can be used without particular limitation. This resin waste material is pulverized to be used as a crushed resin waste material, and the particle size of the crushed resin waste material is preferably 5 mm or less. If the particle size of the pulverized resin waste material exceeds 5 mm, the particles of the pulverized resin waste material may cause unevenness on the surface of the building board, which may cause a problem in appearance, which is not preferable. The lower limit of the particle size of the pulverized resin waste material is not particularly set, but the lower limit is preferably about 1 mm.

Then, a molding material is prepared by blending the pulverized resin waste material with an unsaturated polyester resin and further blending an inorganic filler, and the molding material is molded to obtain a building board according to the present invention. You can Here, the unsaturated polyester resin may be a general one used in the production of building boards, and may be used without any particular limitation, but an ortho resin having no thixotropy property is preferable. The amount of the crushed resin waste material mixed is preferably set in the range of 50 to 100 parts by weight of the crushed resin waste material with respect to 100 parts by weight of the unsaturated polyester resin. Compounding amount of crushed resin waste is 50
If it is less than 100 parts by weight, the effect of recycling the waste material becomes insufficient, and if it exceeds 100 parts by weight, physical properties such as strength of the building board may be adversely affected.

The above-mentioned inorganic filler is not particularly limited, but calcium carbonate is preferably used in the present invention. As the inorganic filler, one having a small particle diameter is used, and one having an average particle diameter of 2 to 300 μm is used. By mixing an inorganic filler with a fine particle size, the dispersibility of the pulverized resin waste material in the molding material is improved, the fluidity of the molding material when casting into the molding die is improved, and the surface is smooth A plate can be molded. Therefore, in the present invention, the average particle size is 300 μm.
The following inorganic fillers are used, and an inorganic filler having an average particle size of more than 300 μm cannot sufficiently obtain the effect of molding a building board with a smooth surface. If the average particle size of the inorganic filler is less than 2 μm, the particle size of the inorganic filler becomes too small, which rather impedes the fluidity of the molding material. Conversely, molding a building board with a smooth surface May be difficult.

The blending amount of the inorganic filler is set within the range of 50 to 200 parts by weight with respect to 100 parts by weight of the unsaturated polyester resin. If the content of the inorganic filler is less than 50 parts by weight, the fluidity of the molding material cannot be increased and the effect of molding a building board with a smooth surface cannot be sufficiently obtained. If the amount exceeds 200 parts by weight, the physical properties of the building board may be adversely affected, and for example, the hot water resistance of the building board may decrease.

As described above, a building board can be molded using a molding material obtained by mixing a pulverized resin waste material and an inorganic filler in an unsaturated polyester resin and mixing them. An example is shown in FIG.
In FIG. 2A, reference numeral 2 is a molding die placed on the molding carriage 1, and the molding die 2 is formed with a molding cavity 3 having an opening on the upper surface. A vibration generator 4 is attached to the molding cart 1. Then, the molding material 5 prepared as described above is poured from the container 6 into the molding cavity 3 as shown in FIG. 2 (b), and the upper lid molding die 7 as shown in FIG. 2 (c).
On the molding die 2 and the vibration generator 4 is actuated to apply vibration to the molding die 2 together with the molding carriage 1,
After defoaming the molding material 5 and smoothing the surface of the molding material 5 in the molding die 2, after completing this work, the vibration generator 4 is stopped and left at room temperature for 30 minutes, and further 60
The building board can be molded by allowing the unsaturated polyester resin to stand for 40 minutes in an atmosphere of ° C to cure the unsaturated polyester resin.

As described above, when the molding material 5 is poured into the molding die 2 for molding, the molding material has improved fluidity due to the incorporation of the inorganic filler, and can be molded with the surface smoothed. A building board A having a smooth surface as shown in FIG. 1 (a) can be obtained. Alternatively, a colored gel coat may be further applied to the surface of the building board A, and a colored gel coat layer 8 may be provided as shown in FIG. 1 (b) to finish the surface. The building board A can be used as a surface decorative board, but can also be used as a reinforcing material in addition to the surface decorative board by stretching it on the back side of the FRP molded product.

[0013]

Next, the present invention will be described by way of examples. (Example 1) FRP containing unsaturated polyester resin and glass fiber as a resin waste material in a weight ratio of 75:25
This FRP waste material was crushed and passed through a 5 mm pass sieve to obtain a crushed FRP waste material having a particle size of 5 mm or less. 75 parts by weight of this pulverized FRP waste material, 1 part by weight of 55% methyl ethyl ketone peroxide (MEKOP), and 6 parts by weight of calcium carbonate having an average particle size of 120 μm were added to 100 parts by weight of unsaturated polyester resin.
A molding material was prepared by blending 0 parts by weight and mixing. Then, this molding material was poured into a molding die as shown in FIG. 2, and after vibrating for 10 minutes, it was left at room temperature for 30 minutes and left at 60 ° C. for 40 minutes to cure the unsaturated polyester resin. Thickness 10m
m building board was obtained. A colored gel coat made of a pigmented unsaturated polyester resin was further applied to this building board, and cured at 50 ° C. for 30 minutes to give a thickness of 400 μm.
m gel coat layer was formed.

(Examples 2 to 5 and Comparative Examples 1 to 4) The same as Example 1 except that calcium carbonate having an average particle size shown in Table 1 was used, and this was blended in the blending amount shown in Table 1. Then, a molding material was prepared, and thereafter, a building board was molded in the same manner as in Example 1. (Conventional example) A molding material was prepared without adding calcium carbonate, and thereafter a building board was molded in the same manner as in Example 1.

[0015]

[Table 1]

As described above, Examples 1 to 5 and Comparative Example 1
The surface smoothness and hot water resistance of the building boards obtained in Examples 4 to 4 and the conventional example were measured. The smoothness is inspected by visual observation, and if no unevenness is observed on the surface, "○",
The case where unevenness was observed on the surface was judged as "x". The hot water resistance test was carried out by immersing in hot water at 90 ° C. for 500 hours, and when no blistering occurred, it was judged as “◯”, and when blistering occurred, it was judged as “x”. Table 2 shows the results.

[0017]

[Table 2]

As can be seen from the results shown in Table 2, each of the examples had good surface smoothness and high hot water resistance.

[0019]

INDUSTRIAL APPLICABILITY As described above, the present invention provides a molding material in which an unsaturated polyester resin is mixed with a crushed resin waste material obtained by crushing a resin waste material containing a thermosetting resin as a main component such as an artificial marble waste material or an FRP waste material. An unsaturated polyester resin as a molding material in a building board obtained by molding
Since 50 to 200 parts by weight of an inorganic filler having an average particle diameter of 2 to 300 μm was blended with 0 part by weight, the fluidity of the molding material was adjusted by blending the inorganic filler having an average particle diameter as described above. It is possible to obtain a building board having a smooth surface by molding in a state where the surface is smooth.

According to a second aspect of the present invention, a crushed resin waste material having a particle size of 5 mm or less is used, and the resin waste material powder is 50 to 100 parts by weight with respect to 100 parts by weight of the unsaturated polyester resin.
It is characterized by being mixed in parts by weight, and the resin waste material can be effectively utilized without affecting the appearance and physical properties of the building board. Further, the invention of claim 3 is characterized in that a colored gel coat layer is provided on the surface, and the surface of the building board can be beautifully finished by the colored gel coat layer.

[Brief description of drawings]

1A and 1B show a building board, wherein FIG. 1A is a schematic view of an example thereof, and FIG. 1B is a schematic view of another example.

FIG. 2 shows an example of molding a building board,
(A), (b), (c) are sectional views, respectively.

[Explanation of symbols]

 2 Mold 5 Molding material 8 Colored gel coat layer

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Claims (3)

[Claims] 1. A building material obtained by molding an unsaturated polyester resin with a crushed resin waste material obtained by crushing a resin waste material containing a thermosetting resin such as an artificial marble waste material or an FRP waste material as a main component. A building board, characterized in that the molding material contains 50 to 200 parts by weight of an inorganic filler having an average particle diameter of 2 to 300 μm with respect to 100 parts by weight of the unsaturated polyester resin. 2. A pulverized resin waste material having a particle size of 5 mm or less is used, and 50 to 100 parts by weight of the pulverized resin waste material is mixed with 100 parts by weight of the unsaturated polyester resin. The building board according to Item 1. 3. The building board according to claim 1, wherein the surface is provided with a colored gel coat layer.