KR101421485B1 - Polycarbonate board with excellent impact resistance, breaking load for bending, warpage and manufacturing method thereof - Google Patents

Abstract

The present invention provides a polycarbonate board with excellent impact resistance and flatness comprising: a substrate layer including 80% or more of polycarbonate resin, adhesive layers formed on either or both surfaces of the substrate layer, and a sheet layer attached to the adhesive layer; and a manufacturing method thereof. The polycarbonate board according to the present invention is easy to convey and manufacture by manufacturing the substrate layer of the board from light polycarbonate resin, is not easily broken or indented owing to excellent strength by excellent impact resistance, has no bending and no distortion when used as a screen for a projector owing to excellent flatness, is not deformed by change in temperature owing to excellent insulation, enables a user to write on the surface of the board sheet freely even with a chalk or a marker pen, and can be manufactured continuously into a large board.

Description

TECHNICAL FIELD [0001] The present invention relates to a polycarbonate blackboard having excellent impact resistance, flexural fracture load, and flatness, and a method of manufacturing the polycarbonate blackboard.

The present invention relates to a blackboard and a method of manufacturing the same, and more particularly, to a polycarbonate board which is formed by joining a lightweight substrate and a sheet, is easily broken and has no bending, and can be continuously formed on a large board.

Generally, the blackboard is used to explain the contents of lectures and lectures in the classroom of the school, lecture room of the academy, office of the company, etc. Recently, it is used as a screen of a projector and used for presenting.

Usually, such a black board is composed of a substrate layer and a sheet layer, and is divided into a green board and a white board, depending on the background color of the sheet layer. The board is classified into a woodboard board using plywood and a steel board using steel sheet, Depending on the type of writing instrument used on the chalkboard, it can be classified as chalkboard or marker pen.

For example, when a PS foam is used as a substrate layer in a conventional blackboard, it is light in weight and is used for manufacturing a large blackboard. However, it may be easily broken, scratches or scratches, Is uneven, flatness is lowered, bending occurs, flammability is generated, and toxic gas is generated at the time of combustion.

Further, when a plywood such as a medium density fiber board (MDF) or a high density fiber board (HDF) is used as a substrate layer in a conventional blackboard, the strength is high and breakage, scratches and scratches are small. However, There is a problem that deformation occurs during use, is vulnerable to fire, and toxic gas is generated when burned.

In addition, when a large blackboard is to be produced, it is necessary to connect several plates together without a continuous plate. In the factory, a board is pressed and adhered to a plurality of plywood sheets to form a blackboard. Most of the stairs or passageways are small, so it is not possible to carry them to the work site while maintaining the size of the large blackboard. As a result, it is necessary to carry several sheets individually to the work site and then apply the adhesive, Because it must be attached with manpower, there is a problem that the adhesion and flatness are lowered and construction is difficult when a large board is manufactured.

In addition, since the PS foam or plywood is weak in adhesion to a blackboard sheet made of steel sheet or synthetic resin (such as PE, PET, PP, and PVC), it is necessary to adhere the board to the PS foam or plywood after bonding the intermediate material There is a problem that it takes a lot of time and construction is troublesome.

In addition, in the case of PS foam or plywood, the adhesive layer is not well adhered and the double-sided tape can not be used. Therefore, it is necessary to attach the sheet using only the adhesive. However, there is a problem in that it is difficult to install in a place where a clean room or a spray adhesive can not be used .

In addition, when synthetic resin such as acryl is used for the substrate layer in the conventional blackboard, it is easily broken or deformed, which is difficult to use continuously for a long time.

Disclosure of Invention Technical Problem [8] The present invention has been made in order to solve all of the problems described above, and it is an object of the present invention to provide a base plate of a blackboard, which is made of lightweight polycarbonate resin and is easy to carry and install, It is easy to carry through a narrow corridor, stairs and corners during the construction of a large black board, and has excellent flatness, so there is no bending. There is no distortion when used on a projector screen. The object of the present invention is to provide a polycarbonate blackboard which can be used continuously with a large blackboard without any deformation due to temperature change because it is excellent in freedom of use and excellent in thermal insulation even when using chalk and marker pen.

In addition, it can be easily and quickly applied because it can be carried out by carrying it to a work site after batch-making it by press-bonding from a factory to a press, and it is possible to manufacture by directly joining a substrate and a sheet without attaching an intermediate material such as a sheet- And it is also intended that the fire is not diffused due to the flame retardancy because toxic gas is not generated in the case of fire.

Further, the present invention is also applied to a field of an electronic blackboard in which honeycomb and aluminum composite panels are used, thereby shortening the production process and reducing the cost by replacing existing substrates.

According to an aspect of the present invention, there is provided a method of manufacturing a liquid crystal display device including a base layer including a polycarbonate resin; An adhesive layer formed on one side or both sides of the base layer; And a sheet layer adhered to the adhesive layer, wherein the polycarbonate blackboard is excellent in impact resistance, flexural strength, and flatness.

At this time, the base layer is also characterized by containing 85 to 95% by weight of a polycarbonate resin, 1 to 10% by weight of a graft copolymer resin, and 0.5 to 5% by weight of an additive.

In addition, the base layer has a thickness of 3 mm to 4.5 mm.

In addition, the bending failure load is 220 N or more.

The adhesive layer is also made of a double-sided tape.

In addition, the sheet layer is characterized in that it is any one selected from a paint-coated steel sheet, an enamel coated steel sheet and a sheet-coated steel sheet.

And a back layer adhered to the adhesive layer formed on the back surface of the base material.

The present invention also relates to a substrate layer comprising a polycarbonate resin; An adhesive layer formed on one surface of the substrate layer; And a sheet layer adhered to the pressure-sensitive adhesive layer, the polycarbonate blackboard being excellent in impact resistance, flexural strength, and flatness.

At this time, the base layer is also characterized by containing 85 to 95% by weight of a polycarbonate resin, 1 to 10% by weight of a graft copolymer resin, and 0.5 to 5% by weight of an additive.

In addition, the base layer has a thickness of 3 mm to 4.5 mm.

In addition, the bending failure load is 220 N or more.

The sheet layer is also characterized by being made of any one selected from PE, PET, PP and PVC.

Further, an adhesive layer formed on the back surface of the substrate layer; And a back layer adhered to the adhesive layer.

Here, the adhesive layer is also made of a double-sided tape.

According to another aspect of the present invention, there is provided a method of manufacturing a coated steel sheet, comprising the steps of: coating a steel sheet with a paint or an enamel or a synthetic resin sheet to form a coated sheet; Applying an adhesive to one side or both sides of a substrate containing a polycarbonate resin or attaching a double-sided tape to form an adhesive layer; Placing a coated sheet on the adhesive layer formed on one side of the substrate, pressing and joining the coated sheet to form a blackboard; And assembling a frame to the outside of the blackboard, the method comprising: preparing a polycarbonate blackboard having excellent impact resistance, flexural strength, and flatness;

At this time, the method further comprises a step of forming a backing layer by bonding a deposition plate to an adhesive layer formed on the back surface of the substrate.

In addition, the present invention provides a method of manufacturing a semiconductor device, comprising: forming an adhesive layer on a surface of any one of synthetic resin sheets selected from PE, PET, PP, and PVC; Bonding the sheet to a base material containing a polycarbonate resin through the adhesive layer to form a blackboard; And assembling a frame to the outside of the blackboard, the method comprising: preparing a polycarbonate blackboard having excellent impact resistance, flexural strength, and flatness;

The step of forming the blackboard may include applying an adhesive to the back surface of the substrate or attaching a double-sided tape to form an adhesive layer; And forming a backing layer by bonding a bonding plate to the adhesive layer.

According to the present invention, since the substrate layer of the blackboard is made of lightweight polycarbonate resin, it is easy to carry and construct, has excellent impact resistance and excellent strength, is not easily broken or recessed, It is easy to carry through narrow corridors, stairs and corners when constructing. It has excellent flatness and has no bending. It does not cause distortion when used as a projector screen. Also, it can be used with chalk and marker pen It is excellent in freedom, excellent in heat insulation, has no deformation due to temperature change, and can be produced continuously on a large board.

In addition, it can be easily and quickly applied because it can be carried out by carrying it to a work site after batch-making it by press-bonding from a factory to a press, and it is possible to manufacture by directly joining a substrate and a sheet without attaching an intermediate material such as a sheet- The cost is reduced, the workability is excellent, the toxic gas is not generated in the fire, and the fire does not spread due to the flame retardancy.

Furthermore, the present invention is applicable to a field of an electronic blackboard in which honeycomb and aluminum composite panels are used, thereby replacing existing substrates, thereby shortening the production process and reducing the cost.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1A and FIG. 1B are perspective views of a polycarbonate blackboard according to an embodiment of the present invention. FIG.
Figures 2a and 2b are cross-sectional views of the incision of Figures 1a and 1b, respectively.
FIG. 3A is a state of use when used as an electronic board, and FIG. 3B is a state of using the apparatus simultaneously with a screen.
4A and 4B are flowcharts of a method of manufacturing a polycarbonate blackboard according to an embodiment of the present invention.
5 is a test result table of a polycarbonate blackboard according to an embodiment of the present invention.
6 is a test result table of the PS foam black board.
7 is a test result sheet of a medium density fiber board (MDF) board.

Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings.

1A and 2A, a polycarbonate blackboard 1 according to a first embodiment of the present invention comprises a substrate layer 10, an adhesive layer 20 and a sheet layer 30, The adhesive layer 40 and the backside layer 50 may be further formed on the back surface of the layer 10.

The base layer 10 serves as a base layer of the polycarbonate blackboard 1 and functions to prevent the sheet layer 30 from being damaged, scratches, scratches, or bending.

The base layer 10 contains a polycarbonate resin as a main component. The polycarbonate resin is a thermoplastic resin produced by reacting bisphenol A with phosgene or the like. The base resin layer 10 is amorphous, transparent, very light, and has mechanical strength But also has the highest impact resistance in the thermoplastic resin and is excellent in heat resistance, flame retardancy, self-extinguishing property, environmental resistance, flexibility and processability, and is widely used in precision machine parts.

At this time, it is preferable that the base layer is composed of 85 to 95% by weight of polycarbonate resin, 1 to 10% of graft copolymer resin, and 0.5 to 5% of other additives in weight%.

As described above, the polycarbonate resin is excellent in mechanical strength and impact resistance and does not easily break or sag, is excellent in heat insulation, has no deformation due to temperature change, and is flame retardant. Therefore, polycarbonate resin is used as a main component in the present invention If it is contained in an amount of more than 95% by weight, the fluidity may be lowered and it may be difficult to process.

The graft copolymer resin may be prepared by grafting a styrene monomer, which is an aromatic vinyl compound, and an acrylonitrile monomer, which is a vinyl cyanide compound, in the presence of a butadiene rubber-like polymer, but is not limited thereto.

For example, the graft copolymer resin may be an acrylonitrile-butadiene-styrene (ABS) copolymer resin.

The content of the graft copolymer resin in the base layer 10 may be from 1 to 10% by weight. If it is less than 1% by weight, the chemical resistance of the base layer 10 may be deteriorated. If it exceeds 10% by weight, Mechanical strength and physical properties may be deteriorated.

The other additives may include at least one selected from a reinforcing agent, a stabilizer, and a lubricant, wherein the reinforcing agent functions to reinforce the impact, the stabilizer functions to stabilize excellent and uniform physical properties, It is preferably used in the pounding to improve the dispersibility or improve the workability. Such other additives are preferably contained in the range of 0.5 to 5%.

The base layer 10 including the polycarbonate resin can bond the sheet layer so that the plate surface of the blackboard is uniform and flat without being affected by the material of the sheet unlike the conventional PS foam or plywood having rough surface roughness, The flatness is excellent and there is no bending and there is no distortion when it is used as a screen of a projector. Therefore, it can be used as an electronic board as shown in FIG. 3A or used for writing simultaneously with a screen as shown in FIG. 3B.

In addition, although the substrate layer 10 is usually made to have a thickness of 3 mm to 6 mm, it is preferred in the present invention to have a thickness of 3 mm to 4.5 mm, because the mechanical strength of the substrate layer 10 containing the polycarbonate resin And impact resistance, so that even if the thickness thereof is reduced, it has excellent physical properties as compared with conventional PS foam or plywood, and the cost increases due to the increase in thickness.

The adhesive layers 20 and 40 are formed on one side or both sides of the base layer 10 so that a sheet layer 30 is attached to the adhesive layer 20 formed on one side, 50 may be attached.

At this time, the adhesive layers 20 and 40 may be formed by applying a commonly used adhesive, but it is preferable to use a double-sided tape because it is more excellent in flatness and workability.

The sheet layer 30 is attached to the adhesive layer 20 formed on one side of the substrate layer 10 to form a plate surface of a blackboard. The sheet layer 30 is a paint-coated steel sheet coated with a coating of green or white paint, An enamel-coated steel sheet, or a sheet-coated steel sheet having a surface coated with a synthetic resin sheet may be used.

These steel sheets are mass-produced continuously by process automation. They have excellent hardness, excellent water resistance, durability, easy handling and erasure, and excellent water retention.

Another backing layer is further adhered to the adhesive layer 40 formed on the back surface of the base material layer 10 so as to be used as a double sided board or a back layer 50 is adhered to finish the back surface of the board, do.

At this time, it is preferable that the backside layer 50 is made of a steel plate. Such a steel plate is a steel plate plated with tin on a thin disk, has excellent gloss, is excellent in corrosion resistance, and is economical.

1B and 2B, a polycarbonate blackboard 1 according to a second embodiment of the present invention comprises a substrate layer 10, an adhesive layer 20 'and a sheet layer 30 The adhesive layer 40 and the back layer 50 may be further formed on the back surface of the base layer 10.

The substrate layer 10 is the same as that described above and the sheet layer 30 is adhered to the adhesive layer 20 'formed on one surface of the substrate layer 10 to form a blackboard surface, PET, PP, and PVC.

At this time, the sheet layer 30 may be a synthetic resin film having a color including green or white to form a plate surface of a blackboard.

The adhesive layer 20 'is preliminarily formed on the back surface of the sheet layer 30, and it is preferable that the adhesive layer 20' should not fall off with strong adhesive force by using the adhesive layer 20 ' Do.

An adhesive layer 40 is formed on the back surface of the substrate layer 10 and another sheet layer is further adhered to the adhesive layer 40 to serve as a double sided board or a back layer 50, And the bending property of the chalkboard is improved.

Of course, it is preferable that the back layer 50 is made of a steel plate, and such a steel plate is a steel plate plated with tin on a thin disk, has excellent gloss, is excellent in corrosion resistance, and is economical.

4A, a method of manufacturing a polycarbonate board according to an embodiment of the present invention includes forming a coating steel sheet (S10), an adhesive layer forming step (S20), a pressing step (S30), and a frame assembly step (S40).

The step (S10) of forming a coated steel sheet is a step of coating a steel sheet with a paint, enamel or synthetic resin sheet to form a coated sheet.

The adhesive layer forming step S20 is a step of applying an adhesive to one surface or both surfaces of a base material containing a polycarbonate resin or attaching a double-sided tape to form the adhesive layers 20 and 40.

In the pressing step S30, a coated sheet is placed on the adhesive layer 20 formed on one side of the base material, and if necessary, the base plate is placed on the adhesive layer 40 formed on the back side of the base material, ) And a back layer (50) are formed on the back surface of the substrate.

Conventionally, in the case of using a PS foam or a plywood, the sheet has a weak adhesive force, and the sheet has to be attached after joining an intermediate material such as a clay sheet. Therefore, the cost is increased and the operation is troublesome. In the case of the polycarbonate blackboard of the present invention Since the layer 10 is excellent in flatness and the sheet 30 can be formed by directly adhering the sheet to the surface of the base layer, the base sheet and the sheet can be directly bonded to each other without intervening in the material of the sheet The cost is reduced and the workability is excellent.

The frame assembling step S40 is a step of assembling and finishing the frame F on the outside of the board.

4B, the method for manufacturing a polycarbonate blackboard according to an embodiment of the present invention includes a pressure-sensitive adhesive layer forming step T10, a blackboard forming step T20, an adhesive layer forming step T30, A layer forming step (T40) and a frame assembling step (T50).

The adhesive layer forming step T10 is a step of forming an adhesive layer 20 'on the surface of any one synthetic resin sheet selected from PE, PET, PP and PVC.

The blackboard forming step T20 is a step of forming a blackboard by bonding the sheet to a base material containing a polycarbonate resin through the adhesive layer 20 '. At this time, since the adhesive layer 20 'is formed on the sheet, it is not necessary to apply the adhesive to the substrate.

The adhesive layer forming step (T30) is a step of applying an adhesive to the back surface of the substrate or attaching a double-sided tape to form the adhesive layer (40).

The backside layer forming step (T40) is a step of forming a backside layer (50) by bonding a seating plate to the adhesive layer (40).

The frame assembling step (T50) is a step of assembling and finishing the frame (F) on the outside of the board.

[ Honor  One]

A sheet made of a 100% polycarbonate resin and having a thickness of 4.5 mm and a steel sheet having a thickness of 0.3 mm coated with a paint was prepared, and the substrate and the sheet were cut to a size of 1.19 m x 2.4 m using a shearing machine Then, an adhesive was applied on the cut substrate to form an adhesive layer, and a sheet was placed on the adhesive layer and bonded by applying a strong pressure using a hydraulic press.

[ Honor  2]

A sheet made of a base material having 90% by weight of a polycarbonate resin, 9% by weight of an ABS copolymer resin, and 1% by weight of an ethylene-ester base lubricant as an additive and having a thickness of 3 mm and a steel sheet having a thickness of 0.3 mm coated with an enamel The substrate and the sheet were cut to a size of 1.19 m x 2.4 m using a shearing machine and then a double-sided tape was attached to the cut base material to form an adhesive layer. The sheet was placed on the adhesive layer, Were added and bonded.

[ Honor  3]

95% by weight of a polycarbonate resin, 4% by weight of an ABS copolymer resin. As another additive, a film made of a substrate made of ethylene-ester-based lubricant of 1 wt% and having a thickness of 4.5 mm and a synthetic resin sheet made of PVC containing white and having a thickness of 0.3 mm was prepared, The sheet was cut to 1.19 m x 2.4 m, and then an adhesive was applied on the cut substrate to form an adhesive layer. A sheet was placed on the adhesive layer and a strong pressure was applied using a hydraulic press.

[ Comparative Example  One]

A sheet made of foamed PS foam having a thickness of 4.5 mm and a sheet made of a steel sheet having a thickness of 0.3 mm coated with a paint was prepared and the substrate and the sheet were cut to a size of 1.19 m x 2.4 m using a shearing machine Next, an adhesive was applied on the cut base material to form an adhesive layer, and the sheet was placed on the adhesive layer and bonded by applying a strong pressure using a hydraulic press.

[ Comparative Example  2]

A sheet made of a medium density fiberboard (MDF) having a thickness of 4.5 mm and a sheet made of a steel sheet having a thickness of 0.3 mm coated with a paint was prepared. Using the shearing machine, the substrate and the sheet were cut to a size of 1.19 m x 2.4 m After cutting, an adhesive was applied on the cut substrate to form an adhesive layer. The sheet was placed on the adhesive layer and bonded by applying a strong pressure using a hydraulic press.

Values of the test evaluation items such as impact resistance, flexural fracture load and flatness were measured for the examples of the samples thus produced, and the test results are shown in Table 1 below.

The impact resistance was measured by fixing the sample on a hard floor and then dropping a ball of 500 g from a height of 1 m to measure the diameter of the defect on the sample.

The flexural failure load was measured by the test method of KS M ISO 1209-1: 2012. Flatness was measured using VICTOR 121510N from Duckin, a contact-type three-dimensional measuring instrument. The test results of Inventive Example 1, Comparative Example 1, and Comparative Example 2 can be seen in FIGS. 5, 6, and 7, respectively.

[Table 1]

As shown in Table 1, Examples 1 to 3 including the polycarbonate base material have excellent impact resistance and bending load resistance compared with Comparative Example 1 including PS foam and 2 including MDF plywood, And it is easy to carry through narrow corridors, stairs and corners because it can bend without breaking.

In Examples 1 to 3, the substrate layer containing polycarbonate was excellent in flatness, and the sheet attached to the substrate was also adhered without bending. Therefore, the flatness was excellent at around 0.5 mm, but the comparison with PS foam Example 1 was not evaluated in the test, but the flatness was undesirably lowered due to the unevenness of the flatness depending on the amount of the adhesive at the time of pressing. In Comparative Example 2 including the MDF plywood, the flatness was not very bad. It can be confirmed that the surface roughness is coarse and the flatness is poor as compared with the inventive examples.

As a result, the polycarbonate blackboard having excellent impact resistance and flatness according to the present invention can be easily manufactured by using a lightweight polycarbonate resin as a substrate layer of the blackboard, and is easy to carry and construct, has excellent impact resistance and excellent strength, , The flatness is excellent and there is no bending, there is no distortion when used on the screen of a projector, and even if a chalk and marker pen is used along the surface of the blackboard, the writing is excellent and the heat insulating property is excellent, It can be manufactured continuously in a large blackboard. Also it can be mass-produced in a factory and transported as individual parts, and it can be bonded at the worksite. It is possible to apply the substrate and sheet directly without intervening the material of the sheet, It is possible to manufacture by joining to reduce cost and workability, And fire is not diffused due to flame retardancy.

The present invention is not limited to the above-described embodiments. Anything having substantially the same constitution as the technical idea described in the claims of the present invention and achieving the same operational effect is included in the technical scope of the present invention.

1. Polycarbonate blackboard
10. Base layer
20. Adhesive layer
20 'adhesive layer
30. Seat layer
40. Adhesive layer
50. The backside layer
F. Frame

Claims (18)

A base layer containing 85 to 95% by weight of a polycarbonate resin, 1 to 10% of a graft copolymer resin, and 0.5 to 5% of an additive and having a thickness of 3 to 4.5 mm;
An adhesive layer formed on both surfaces of the substrate layer;
A sheet layer made of a coated steel sheet and attached to an adhesive layer formed on one side of the base layer; And
And a backside layer made of a clay plate and attached to an adhesive layer formed on the back surface of the base layer,
A flexural fracture load of 220 N or more, and a flatness of 0.5 mm or less, wherein the polycarbonate blackboard has excellent impact resistance, bending load and flatness.
The method according to claim 1,
Wherein the sheet layer is any one selected from a paint-coated steel sheet, an enamel-coated steel sheet, and a sheet-coated steel sheet, wherein the sheet layer is excellent in impact resistance, flexural strength, and flatness.
Coating a steel sheet with a paint or an enamel or a synthetic resin sheet;
An adhesive layer is formed by applying an adhesive on both sides of a substrate layer containing 85 to 95% by weight of a polycarbonate resin, 1 to 10% by weight of a graft copolymer resin and 0.5 to 5% by weight of an additive and having a thickness of 3 to 4.5 mm ;
Placing the coated steel sheet on the adhesive layer formed on one surface of the base layer, pressing and bonding the coated steel sheet to form a sheet layer;
Forming a backing layer on the adhesive layer formed on the rear surface of the substrate layer, the backing layer being formed by pressing and bonding the deposition board; And
And assembling a frame on an outer periphery of the blackboard. The method of manufacturing a polycarbonate board according to claim 1,



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