KR102626561B1 - Synthetic polymer deck containing thermoset foam powder - Google Patents

Abstract

The present invention relates to a synthetic resin deck, and more specifically, to a synthetic resin deck containing any one or two or more foam powders selected from ground phenol foam powder and ground polyurethane foam powder. Since the synthetic resin deck according to one aspect of the present invention is made only of synthetic resin and does not contain wood flour, production costs can be reduced, and discarded resources can be recycled, thereby providing a carbon reduction effect.
In addition, as the foam is pulverized and incorporated into powder, there is no shrinkage of the foam, excellent adhesion to the polyolefin resin, which is the base material, and excellent compression processability, enabling mass production.
In addition, the maximum tunnel load according to KS F 3230 is more than 4000 N, the moisture absorption rate is less than 1%, and the impact strength change rate is more than 90%, providing physical properties suitable for application to decks by replacing existing natural wood or synthetic wood. can do.

Description

Synthetic resin deck containing foam powder {SYNTHETIC POLYMER DECK CONTAINING THERMOSET FOAM POWDER}

The present invention relates to a synthetic resin deck, and more specifically, to a synthetic resin deck containing one or more thermosetting foam powders selected from ground phenol foam powder and ground polyurethane foam powder.

Decks are generally used as building materials for walking on hiking trails, trails, and pedestrian paths. Deck materials vary, but natural wood or synthetic wood containing wood flour are widely used. Natural wood is vulnerable to heat and fire, has low strength, and may shrink and expand due to climate change, resulting in cracking.

To compensate for this, there is synthetic wood (WOOD PLASTIC COMPOSITE) made by adding wood flour to synthetic resin and extruding it. Synthetic resins used in synthetic wood are usually polyethylene, polypropylene, and polyvinyl chloride, and wood flour is made from recycled tree products, wood chips, and sawdust. This synthetic wood maintains the texture of natural wood and has improved durability and strength compared to natural wood, but its high specific gravity increases the weight of the construction object, and its lack of flame retardancy limits its application to interior and exterior building materials.

As an example of such synthetic wood, Korea Patent Publication No. 10-2014-0092653 (July 24, 2014) discloses a synthetic wood having a foamed resin layer to reduce weight and reduce costs by forming a highly foamed resin on the inner layer. It was disclosed. However, as the inner layer contains foam, the adhesion between the foam and the surface layer is not smooth, and a process for foaming the inner layer foam is required, which has the disadvantage that shrinkage may occur in the foam.

Korean Patent Publication No. 10-2014-0092653 (2014.07.24.)

The present invention seeks to provide a synthetic resin deck that can replace natural wood and synthetic wood containing wood flour, which has been used as a material for conventional decks.

In addition, we aim to provide a synthetic resin deck that is light in weight, has excellent strength, and has excellent moisture resistance.

In addition, we aim to provide a synthetic resin deck that can prevent environmental pollution and reduce production costs by recycling foam that is generated as a by-product or discarded as waste in the process of manufacturing insulation materials using foam.

In addition, the aim is to provide a synthetic resin deck that has excellent physical properties such as strength and is easy to form even though by-products or waste are used.

In addition, by pulverizing the foam and incorporating it into powder, there is no shrinkage of the foam, the adhesion to the polyolefin resin, which is a base material, is improved, and the extrusion processability is excellent to provide a synthetic resin deck that can be mass-produced.

One aspect of the present invention for achieving the above problem is a synthetic resin deck composed of a skin layer forming the outer surface and a core layer forming the inner surface,

The core layer is composed of 20 to 80 parts by weight of polyolefin resin and 0.1 to 10 parts by weight of acid-modified polyolefin, based on 100 parts by weight of foam powder selected from ground phenol foam powder and ground polyurethane foam powder, or a mixture thereof. and 0.1 to 5 parts by weight of a processing enhancer selected from fluorocarbon resins or fatty acid compounds,

The skin layer is composed of 10 to 120 parts by weight of foam powder selected from ground phenol foam powder or ground polyurethane foam powder or a mixture thereof, and 0.1 to 10 parts by weight of acid-modified polyolefin, based on 100 parts by weight of polyolefin resin. and 0.1 to 5 parts by weight of a processing enhancer selected from fluorocarbon resins or fatty acid compounds.

In one aspect, the skin layer and the core layer may further include one or more additives selected from the group consisting of pigments, fillers, antioxidants, sunscreens, and flame retardants.

In one aspect, the pigment may be any one selected from kaolin and titanium oxide (TiO ₂ ) or a mixture thereof.

In one aspect, the foam powder may be a powder obtained by pulverizing foam that is discarded or a by-product generated during the production of phenol foam and polyurethane foam. The foam may be hard phenolic foam or hard polyurethane foam.

In one aspect, the core layer and the skin layer may further include 1 to 20 parts by weight of polyethylene-based elastomer with a density of 0.850 to 0.910 g/cm ³ . More preferably, the skin layer may further include 1 to 20 parts by weight of polyethylene-based elastomer with a density of 0.850 to 0.910 g/cm ³ .

In one aspect, the core layer and the skin layer may further include 0.1 to 10 parts by weight of polymethyl methacrylate resin. More preferably, the skin layer may further include 0.1 to 10 parts by weight of polymethyl methacrylate resin.

In one aspect, the average particle size of the foam powder may be 5 to 500 ㎛, but is not limited thereto.

In one aspect, the polyolefin-based resin may have a melt index of 0.1 to 50 g/10 min at 230°C and 2.16 kg, but is not limited thereto.

In one aspect, the total thickness of the synthetic resin deck may be 10 to 50 mm, but is not limited thereto.

In one aspect, the core layer may have a thickness of 10 to 45 mm, and the skin layer may have a thickness of 0.1 to 5 mm, but are not limited thereto.

In one aspect, the synthetic resin deck may have a maximum bending load of 3500 N or more according to KS F 3230, a moisture absorption rate of 1% or less, and an impact strength change rate of 90% or more, but is not limited thereto.

Since the synthetic resin deck according to one aspect of the present invention is made only of synthetic resin and does not contain wood flour, production costs can be reduced, and discarded resources can be recycled, thereby providing a carbon reduction effect.

In addition, as the foam is pulverized and incorporated into powder, there is no shrinkage of the foam, excellent adhesion to the polyolefin resin that is the base material, and excellent extrusion processability can provide the effect of enabling mass production.

In addition, the maximum bending load according to KS F 3230 is more than 3500 N, the moisture absorption rate is less than 1%, and the impact strength change rate is more than 90%, providing properties suitable for application to decks by replacing existing natural wood or synthetic wood. can do.

Figure 1 shows a synthetic resin deck according to one aspect of the present invention.

Hereinafter, the present invention will be described in more detail. However, the following specific examples or examples are only a reference for explaining the present invention in detail, and the present invention is not limited thereto, and may be implemented in various forms.

Additionally, unless otherwise defined, all technical and scientific terms have the same meaning as commonly understood by one of ordinary skill in the art to which the present invention pertains. The terminology used in the description herein is merely to effectively describe specific embodiments and is not intended to limit the invention.

Additionally, as used in the specification and the appended claims, the singular forms “a,” “an,” and “the” are intended to also include the plural forms, unless the context clearly dictates otherwise.

Additionally, when a part "includes" a certain component, this means that it may further include other components rather than excluding other components, unless specifically stated to the contrary.

Additionally, unless otherwise specified in the present invention, when a layer or member is said to be located “on” another layer or member, this means not only when a layer or member is in contact with another layer or member, but also when a layer or member is located “on” another layer or member. This also includes cases where another layer or another member exists in between.

In addition, the terms “about”, “substantially”, etc. used in this specification are used at or close to the numerical value when manufacturing and material tolerances inherent in the mentioned meaning are presented, and are used to aid understanding of the present invention. It is used to prevent unscrupulous infringers from unfairly using disclosures that contain precise or absolute figures.

The inventors of the present invention completed the present invention as a result of research to provide a deck that is lightweight, has excellent strength, and has excellent water resistance, and is made of synthetic resin material without using wood or wood flour, but can give a wood-like feel. . Specifically, a deck that has excellent strength and water resistance and is easy to process while recycling foam that is generated as a by-product or discarded as waste in the process of manufacturing insulation materials using foam such as phenol foam and polyurethane foam. As a result of research to provide a , the present invention was completed by discovering that the desired effect could be achieved by mixing and using specific ingredients.

Hereinafter, a synthetic resin deck according to an aspect of the present invention will be described with reference to the attached drawings.

A synthetic resin deck according to one aspect of the present invention is shown in Figure 1. As shown in FIG. 1, it may be composed of a skin layer 10 forming the outer surface and a core layer 20 forming the inner surface. As shown in Figure 1, the skin layer is formed to surround the outer peripheral surface of the core layer and forms the outer surface.

The synthetic resin deck according to one aspect of the present invention may be manufactured by co-extruding a composition for a skin layer and a composition for a core layer.

In one embodiment, 20 to 80 parts by weight of polyolefin-based resin and 0.1 to 10 parts by weight of acid-modified polyolefin, based on 100 parts by weight of foam powder selected from ground phenol foam powder and ground polyurethane foam powder, or a mixture thereof. and 0.1 to 5 parts by weight of a processing enhancer selected from fluorocarbon resins or fatty acid compounds.

In addition, based on 100 parts by weight of polyolefin resin, 10 to 120 parts by weight of foam powder selected from ground phenol foam powder or ground polyurethane foam powder or a mixture thereof, 0.1 to 10 parts by weight of acid-modified polyolefin, and fluorine. A second mixture is prepared containing 0.1 to 5 parts by weight of a processing enhancer selected from resin or fatty acid compound.

An integrated deck can be manufactured by co-extruding the first mixture as a core layer and the second mixture as a skin layer through each die.

When manufacturing a deck by co-extrusion as described above, after extruding the mixture containing foam powder, volume expansion occurs when it passes through the ellipse of the extruder, and the surface may become bumpy during cooling. As in one aspect of the present invention, the surface can be formed smooth and uniform by including a processing enhancer.

In one aspect, the total thickness of the synthetic resin deck may be 10 to 50 mm, but is not limited thereto.

In one aspect, the thickness of the skin layer is not limited, but may be specifically, for example, 0.1 to 5 mm, and the thickness of the core layer is not limited, but may be specifically, for example, 10 to 45 mm. It may be mm.

In one aspect, since the skin layer forms the surface, it is better to have excellent strength and functionality such as slip resistance. In order to achieve these physical properties, 1 to 20 parts by weight of polyethylene-based elastomer may be further included in the skin layer, if necessary.

In addition, in order to provide surface gloss and surface smoothness to the skin layer, 0.1 to 10 parts by weight of polymethyl methacrylate resin may be further included as needed.

Additionally, if necessary, the skin layer and core layer may further include one or more additives selected from the group consisting of pigments, fillers, sunscreens, and flame retardants. The pigment is used to provide color, and may be included in the skin layer to provide color. The content is not limited as it can be any content suitable for imparting color. The filler may use inorganic particles such as talc or calcium carbonate, and may reinforce strength. The content may include 0.1 to 50 parts by weight, and is not limited thereto as it can be adjusted and used as needed. The sunscreen and flame retardant are not limited as long as they are commonly used in the relevant field, and their content is also not limited as it can vary depending on the purpose.

As the synthetic resin deck according to one aspect of the present invention combines a skin layer and a core layer of a specific composition, the maximum bending load according to KS F 3230 is 3500 N or more, more preferably 4000 N or more, more specifically 3500 to 5500 N. and the moisture absorption rate is 8% or less, 5% or less, more preferably 1% or less, specifically 0.1 to 1%, and the impact strength change rate is 80% or more, more preferably 90% or more, more specifically 90 to 95%. physical properties can be satisfied at the same time.

Hereinafter, each component of the synthetic resin deck of the present invention will be described in more detail.

[Foam powder]

In one aspect, the foam powder can be used as a by-product discarded after cutting in the process of producing phenol foam insulation or polyurethane insulation, or foam discarded after construction. Accordingly, production costs can be further reduced because a separate foaming process is not required, and a carbon reduction effect can be provided from the perspective of recycling waste resources.

By pulverizing the foam and adding it in powder form, it can be mixed with the polyolefin-based resin that forms the base material to achieve greater strength. In addition, as it is added in powder form, it can be added not only to the core layer of the deck but also to the skin layer, so it can be added in a larger amount.

In one aspect, the average particle diameter of the foam powder is not limited, but may be 5 to 500 ㎛, 10 to 400 ㎛, 20 to 300 ㎛, and 30 to 250 ㎛. It is possible to add a larger amount within the above range, and it is good because it can have excellent extrusion moldability when extruded by compounding with polyolefin resin and excellent mechanical properties such as the strength of the manufactured deck, but is not limited to this.

In one aspect, the density of the foam powder may be 1.0 to 1.4 g/㎥, more specifically 1.1 to 1.2 g/㎥, and is preferred because it is easy to grind in this range, but is not limited thereto. In one aspect, when the density of the foam is lower than the above range, the density can be adjusted to the above range through the process of compressing the foam. Additionally, if the density is too high, grinding may be difficult, so it is preferable within the above range, but is not limited thereto.

In addition, the phenolic foam and polyurethane foam may be made of hard phenol foam and hard polyurethane foam, and it is preferable to provide a deck with better strength by using such hard foam, but it is not limited thereto. no.

The foam powder may be included in greater amounts in the core layer than in the skin layer, but is not limited to this.

[Polyolefin resin]

In one aspect, the polyolefin-based resin is a polypropylene homopolymer, which contains propylene as a main component and is composed of α-olefins having 2 to 20 carbon atoms such as ethylene, 1-butene, 4-methyl-pentene-1, hexene, octene, decene, etc. Examples include polypropylene random or block copolymers prepared by copolymerization, low-density polyethylene, linear low-density polyethylene, medium-density polyethylene, high-density polyethylene, polybutylene, and poly4-methyl-pentene-1.

In one aspect, the polyolefin-based resin has a melt index of 0.1 to 50 g/10min, 1 to 40 g/10min, 5 to 30 g/10min, and 7 to 15 g/10min at 230 ° C. and 2.16 kg. It may be desirable because it has good processability when compounding and has excellent extrusion processability, but is not limited thereto.

[Acid modified polyolefin]

In one aspect, the acid-modified polyolefin may be used to improve compatibility and miscibility between the foam powder and the polyolefin-based resin. One aspect of the acid-modified polyolefin includes polyolefin modified with an acid-modified group such as a carboxyl group or an acid anhydride group. Among them, polyolefin modified with a carboxyl group is preferable. In addition, in this specification, “carboxyl group” refers to a concept that also includes “anhydrous carboxyl group”, unless otherwise specified.

More specifically, the acid-modified polyolefin may be an acid-modified polyolefin in which an acid-modified group is grafted onto the polyolefin.

It is more preferable that the acid-modified polyolefin grafted with an acid-modified group and the acid-modified polyolefin copolymerized with an acid-modified group are resins that do not have unsaturated bonds in the main chain.

As the polyolefin related to the acid-modified polyolefin to which the acid-modified group has been grafted (in other words, the polyolefin before the acid-modified group has been grafted), polyethylene, polypropylene, and olefin copolymer can be used.

Examples of the olefin copolymer include propylene-α-olefin copolymer, olefin-cyclic olefin copolymer, and olefin-styrene copolymer.

Propylene-α-olefin copolymer is a copolymer obtained by further copolymerizing propylene with α-olefin. Examples of α-olefins include ethylene, 1-butene, 1-heptene, 1-octene, and 4-methyl-1-pentene. These α-olefins can be used individually or in combination of two or more types. Additionally, you may copolymerize by combining monomers other than vinyl acetate. Examples of the olefin-cyclic olefin copolymer include copolymers of ethylene or propylene and tetracyclododecene.

As olefin-styrene-based copolymers, styrene-butadiene copolymer, styrene-ethylenepropylene copolymer, styrene-butadiene-styrene copolymer, styrene-isoprene-styrene copolymer, styrene-ethylenebutylene-styrene copolymer, and styrene-ethylene. Propylene-styrene copolymer, etc. are exemplified.

The method for producing the acid-modified polyolefin to which the acid-modified group has been grafted is not particularly limited, and known methods can be used. For example, a radical grafting reaction of polyolefin can be used, and more specifically, a radical species is generated from the polymer that serves as the main chain, and the radical species is used as a polymerization initiation point to form an unsaturated carboxylic acid and/or an unsaturated carboxylic acid. A method of graft polymerizing an acid anhydride is included.

Examples of the unsaturated carboxylic acid and/or unsaturated carboxylic acid anhydride include unsaturated monoacrylic acid, such as acrylic acid, butanoic acid, crotonic acid, vinylacetic acid, methacrylic acid, pentenoic acid, dodecenoic acid, linoleic acid, angelic acid, and cinnamic acid. Examples include unsaturated dicarboxylic acids such as carboxylic acid, maleic acid, fumaric acid, chloromaleic acid, and hymic acid, and unsaturated carboxylic acid anhydrides such as maleic anhydride, hymic acid anhydride, and acrylic anhydride. Among these, maleic anhydride can be used particularly suitably.

The weight average molecular weight of the acid-modified polyolefin is preferably, for example, 5000 to 400,000 g/mol, and more preferably 3000 to 200,000 g/mol. Weight average molecular weight is measured by gel permeation chromatography (GPC). It is obtained by comparing the weight average molecular weight measured under the same conditions by GPC with already known polystyrene.

The acid value of the acid-modified polyolefin is not particularly limited, but the acid value is preferably 0.5 to 500 mgKOH/g, and more preferably 2 to 300.

The functional group equivalent of the acid-modified group of the acid-modified polyolefin is preferably 100 to 50,000 g/mol, and more preferably 200 to 30,000 g/mol.

Although not particularly limited, when used in the core layer, the acid-modified polyolefin may be used in an amount of 0.1 to 10 parts by weight based on 100 parts by weight of the foam powder, and when used in the skin layer, the acid-modified polyolefin may be used in an amount of 0.1 to 10 parts by weight of the polyolefin resin. It may be used in an amount of 0.1 to 10 parts by weight.

In addition, acid-modified polyolefin can be used individually or in combination of two or more types.

[Processing improver]

In one aspect, in order to further improve extrusion moldability during co-extrusion of the core layer and the skin layer, 0.1 to 5 parts by weight of a processing enhancer selected from fluorocarbon resins or fatty acid compounds may be included.

Since the fluoropolymer contains expanded foam powder, it expands in volume when it passes through the ellipse of the extruder after extrusion, and the surface becomes bumpy when cooled. However, using fluoropolymer can provide a smooth and uniform surface.

Such fluoropolymers may be, for example, homopolymers of vinylidene fluoride (VDF), vinylidene fluoride copolymers, or mixtures of the above materials. Specifically, for example, vinylidene fluoride Homopolymer of; mixtures of copolymers of vinylidene fluoride and other fluorine-based monomers; and mixtures of vinylidene fluoride homopolymers and vinylidene fluoride copolymers.

In one embodiment, when using a homopolymer of vinylidene fluoride, a copolymer of vinylidene fluoride, or a mixture of the above materials, the vinylidene fluoride monomer is contained in an amount of 60 to 90 mol% based on the total number of moles of the fluoropolymer. It is preferable, and it is more preferable that it is contained in 80 to 90 mol%. If the vinylidene fluoride monomer is included in less than 60 mol% relative to the total number of moles of the fluoropolymer, there may be difficulty in achieving the desired processing improvement.

In addition, when using a mixture of vinylidene fluoride and other fluorine-based monomers as a fluororesin, if the ratio of other fluorine-based monomers to the total number of moles of fluororesin is higher than that of vinylidene fluoride, it is difficult to select a solvent for coating the composition on the substrate. There is.

In one aspect, the vinylidene fluoride copolymer may be a fluorinated comonomer including fluoroolefin, fluorovinyl ether, or fluorodioxole.

The fluorinated comonomers include tetrafluoroethylene (TFE), hexafluoropropylene (HFP), chlorotrifluoroethylene (CTFE), trifluoroethylene, hexafluoroisobutylene, perfluorobutylethylene, and purple. Fluoropropyl vinyl ether (PPVE), perfluoroethyl vinyl ether (PEVE), perfluoromethyl vinyl ether (PMVE), perfluoro-2,2-dimethyl-1,3-dioxole (PDD), and purple One or more types may be selected and used from the group including luoro-2-methylene-4-methyl-1,3-dioxolane (PMD).

In one aspect, the fatty acid compound may be a saturated or unsaturated fatty acid compound having 1 to 20 carbon atoms. Specifically, for example, oleic acid, palmitic acid, ethylhexanoic acid, and linolenic acid can be used.

[additive]

In one aspect, the synthetic resin deck of the present invention may further include one or more additives selected from the group consisting of pigments, fillers, sunscreens, antioxidants, and flame retardants in the skin layer and the core layer. Even better, it can be included only in the skin layer.

The pigment may be used without limitation as long as it is used in the relevant field. As a specific and non-limiting example, the white pigment among the pigments may be rutile type titanium dioxide (TiO ₂ ), and the colored pigment may be metal. Inorganic pigments containing, for example, iron oxide-based inorganic pigments, etc. can be used.

The sunscreen can be used without limitation as long as it is used in the relevant field. For example, CIBA's Tinuvin-P, etc. can be used.

The antioxidant can be used without limitation as long as it is a commonly used antioxidant material, such as 2.2-methylenebis(4-methyl-6-t-butylphenol) and 2.6-di-t-butyl-4-methylphenol. One or more than two selected may be used, but are not limited thereto. As a specific example, the antioxidant may include 0.5 to 10 parts by weight, more preferably 0.5 to 5 parts by weight, and even more preferably 0.5 to 1 part by weight. This range is desirable because it can exhibit excellent miscibility, but is not limited thereto.

The filler may be any one of the group consisting of one or a combination of two or more selected from the group consisting of calcium carbonate, silica, talc, vermiculite, mica, aluminum hydroxide, aluminum oxide, and barium sulfate. The strength can be further strengthened by adding the filler, and the content is not limited, but is for example 0.1 to 50 parts by weight, 10 to 50 parts by weight, more preferably 15 to 50 parts by weight, more preferably 15 to 50 parts by weight. It may contain 40 parts by weight.

The flame retardant may be used without limitation as long as it is used in the relevant field, and may include, for example, one or more selected from the group consisting of vermiculite, inorganic flame retardant, and combinations thereof. The inorganic flame retardant may include magnesium hydroxide, aluminum hydroxide, etc.

[Polyethylene-based elastomer]

In one aspect, by adding polyethylene-based elastomer to the core layer and skin layer of the synthetic resin deck to provide elasticity, mechanical strength can be further improved, and anti-slip and elasticity can be provided.

The polyethylene-based elastomer has an ethylene content of 70 to 95% by weight, and contains propylene, 1-butene, 1-pentene, 1-hexene, 1-heptene, 1-octene, 1-nonene, 1-decene, and 1-dodecene. Ethylene-alpha-olefin copolymer-based elastomers with an alpha-olefin content of 5 to 30% by weight, such as polyethylene multiblock copolymers composed of high-density or medium-density ethylene-alpha-olefin hard blocks and low-density ethylene-alpha-olefin soft blocks System elastomers can be used. Specific examples include those having a density of 0.850 to 0.910 g/cm3, and more specifically commercialized examples include polyethylene-1-butene copolymer elastomer, Mitsui Chemicals' product name Tafmer DF640, A4085S, H-1035S, polyethylene multi-block copolymer. Elastomers, such as Dow Chemicals' product names INFUSE D9000, D9007, D9100, D9107, D9500, D9507, D9530, D9817, D9807, etc., are not limited thereto.

The polyethylene-based elastomer is preferably included in the skin layer, and its content is preferably 1 to 20 parts by weight, but is not limited thereto.

[polymethyl methacrylate resin]

In one aspect, polymethyl methacrylate resin may be further added to the core layer and skin layer of the synthetic resin deck. In particular, surface smoothness and surface gloss can be provided by adding more to the skin layer. The content may be 0.1 to 10 parts by weight, but is not limited thereto.

The present invention will be described in more detail below based on examples and comparative examples. However, the following Examples and Comparative Examples are only one example to explain the present invention in more detail, and the present invention is not limited by the following Examples and Comparative Examples.

The physical properties were evaluated as follows.

1) Weight average molecular weight

The weight average molecular weight of the resin was measured at 140°C using GPC (Waters 150C) using o-dichlorobenzene as a solvent and polystyrene as a standard.

2) Evaluation of maximum bending load, moisture absorption and weather resistance

Maximum bending load, moisture absorption, and weather resistance evaluation were measured according to KS F 3230.

[Example 1]

For 100 parts by weight of pulverized phenol foam insulation powder (average particle diameter 150 ㎛), 50 parts by weight of polypropylene random copolymer as a polyolefin resin with a melt index (230°C, 2.16kg) 7.0 g/10min, carboxylic acid modified A core layer composition was prepared by mixing 5 parts by weight of polyolefin (weight average molecular weight 12,000 g/mol, acid value 100 mgKOH/g) and 3 parts by weight of palmitic acid.

50 parts by weight of powder (average particle diameter 150 ㎛), modified with carboxylic acid, based on 100 parts by weight of polypropylene random copolymer with a melt index (230℃, 2.16kg) of 7.0 g/10min as a polyolefin resin. A skin layer composition was prepared by mixing 5 parts by weight of polyolefin (weight average molecular weight 12,000 g/mol, acid value 100 mgKOH/g) and 3 parts by weight of palmitic acid.

The core layer composition and the skin layer composition were kneaded in each extruder, and then co-extruded through a co-extruder so that the skin layer composition surrounded the outer peripheral surface of the core layer as shown in FIG. 1 to manufacture a synthetic resin deck.

As a result of measuring the physical properties of the manufactured deck, it was confirmed that the maximum bending load was 4016 N, the moisture absorption rate was 0.8%, and the impact strength change rate was 93%, satisfying the quality standard KS F 3230. In addition, it was confirmed that corrosion due to moisture was less and mold did not occur compared to the existing composite wood deck using wood flour.

[Example 2]

In Example 1, a synthetic resin deck was manufactured in the same manner as in Example 1, except that 15 parts by weight of artificial marble powder (average particle diameter 120 ㎛) obtained by pulverizing discarded artificial marble was added to the skin layer composition.

As a result of measuring the physical properties of the manufactured deck, it was confirmed that the maximum bending load was 4018 N, the moisture absorption rate was 0.8%, and the impact strength change rate was 93%, satisfying the quality standard KS F 3230.

[Example 3]

In Example 1, except that 10 parts by weight of polyethylene-1-butene copolymer elastomer with a density of 0.870 g/cm ³ and a melt index (190° C., 2.16 kg) of 3.6 (g/10 min) was added to the skin layer composition. Then, a synthetic resin deck was manufactured in the same manner as Example 1.

As a result of measuring the physical properties of the manufactured deck, it was confirmed that the maximum bending load was 4025 N, the moisture absorption rate was 0.7%, and the impact strength change rate was 95%, satisfying the quality standard KS F 3230.

[Example 4]

In Example 1, a synthetic resin deck was manufactured in the same manner as Example 1, except that 2 parts by weight of polymethyl methacrylate resin was added to the skin layer composition.

As a result of measuring the physical properties of the manufactured deck, it was confirmed that the maximum bending load was 4017 N, the moisture absorption rate was 0.8%, and the impact strength change rate was 93%, satisfying the quality standard KS F 3230. In addition, it was confirmed that the surface of the manufactured product was smooth and smoothness was improved.

[Example 5]

In Example 1, a synthetic resin deck was manufactured in the same manner as Example 1, except that 10 parts by weight of calcium carbonate was added to the skin layer and core layer composition.

As a result of measuring the physical properties of the manufactured deck, it was confirmed that the maximum bending load was 4020 N, the moisture absorption rate was 0.8%, and the impact strength change rate was 93%, satisfying the quality standard KS F 3230.

As described above, the present invention has been described with specific details and limited embodiments, but these are provided only to facilitate a more general understanding of the present invention, and the present invention is not limited to the above embodiments, and the field to which the present invention pertains is not limited to the above embodiments. Those skilled in the art can make various modifications and variations from this description.

Accordingly, the spirit of the present invention should not be limited to the described embodiments, and the scope of the patent claims described below as well as all modifications that are equivalent or equivalent to the scope of this patent claim shall fall within the scope of the spirit of the present invention. .

10: skin layer
20: core layer

Claims (11)

It is a synthetic resin deck composed of a skin layer forming the outer surface and a core layer forming the interior,
The core layer is composed of 20 to 80 parts by weight of polyolefin resin and 0.1 to 10 parts by weight of acid-modified polyolefin, based on 100 parts by weight of foam powder selected from ground phenolic foam powder and ground polyurethane foam powder, or a mixture thereof. and 0.1 to 5 parts by weight of a processing enhancer selected from fluororesins or fatty acid compounds,
The skin layer is composed of 10 to 120 parts by weight of foam powder selected from ground phenol foam powder or ground polyurethane foam powder or a mixture thereof, and 0.1 to 10 parts by weight of acid-modified polyolefin, based on 100 parts by weight of polyolefin resin. and 0.1 to 5 parts by weight of a processing enhancer selected from fluororesins or fatty acid compounds,
The synthetic resin deck has a maximum bending load of 3500 N or more according to KS F 3230, a moisture absorption rate of 1% or less, and an impact strength change rate of 90% or more.
According to clause 1,
A synthetic resin deck wherein the skin layer and the core layer further include one or more additives selected from the group consisting of pigments, fillers, antioxidants, sunscreens, and flame retardants.
According to clause 2,
A synthetic resin deck in which the pigment is titanium dioxide (TiO ₂ ).
According to clause 1,
The foam powder is a synthetic resin deck that is a powder obtained by pulverizing foam that is discarded or a by-product generated during the production process of phenol foam and polyurethane foam.
According to clause 1,
The skin layer is a synthetic resin deck further comprising 1 to 20 parts by weight of polyethylene-based elastomer with a density of 0.850 to 0.910 g/cm ³ .
According to clause 1,
The skin layer is a synthetic resin deck further comprising 0.1 to 10 parts by weight of polymethyl methacrylate resin.
According to clause 1,
A synthetic resin deck in which the foam powder has an average particle size of 5 to 500 ㎛.
According to clause 1,
The polyolefin-based resin is a synthetic resin deck having a melt index of 0.1 to 50 g/10 min at 230 ° C. and 2.16 kg.
According to clause 1,
A synthetic resin deck having a total thickness of 10 to 50 mm.
According to clause 9,
The thickness of the core layer is 10 to 45 mm,
A synthetic resin deck where the skin layer has a thickness of 0.1 to 5 mm.
delete