JP2002302914A - panel - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an inexpensive panel excellent in surface design and excellent in soundproofing, strength and lightness, particularly a soundproofing panel, as a means for promoting material recycling of FRP molded articles. And a panel useful as a wall panel. . SOLUTION: From above, a surface layer (A), a core material layer (B), a surface layer
In the panel consisting of (A), the surface layer (A) is made of FRP
The core material layer (B) is a layer obtained by consolidating the finely crushed product of the FRP molded product with the thermosetting resin. , Its density is 0.8 ~
A panel characterized by being 1.4 g / cm ³ .

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a panel which effectively uses a crushed waste FRP molded product. More specifically, the present invention relates to a panel having excellent surface design, soundproofing, strength, and lightness as a soundproofing panel or a wall panel.

[0002]

2. Description of the Related Art Conventionally, soundproof walls provided on the side portions of roads and railways have been made of ceramics, resins, metal panels, and the like.
Concrete panels and the like are used.

[0003] The soundproofing board and the soundproofing wall are selected in consideration of the installation place, the workability, the soundproofing, the soundproofing properties, the price and the like. Conventionally, the main purpose of a railway or a motorway has been to prevent noise pollution. Further, soundproof walls on general roads, construction sites, and the like require aesthetic appearance in construction as well as soundproofing characteristics. However, in the conventional soundproof wall, it has been hardly performed to design the soundproof wall itself to impart aesthetic appearance or a function as an advertising medium.
In the case of a small area, the purpose was achieved by painting or pasting by hand, but in this case, the price was relatively expensive, and there was a natural restriction on its spread.

[0004] On the other hand, in today's day when the formation of a recycling-oriented society is becoming important for the preservation of the global environment, design or product development in consideration of product reuse and material recycling has become extremely important.

[0005] Unsaturated polyester resins have excellent properties such as heat resistance and easy processability in various molding methods, and the molded articles have good surface conditions, so that they can be used for various purposes. Have been. However, when discarding these products, landfills are currently used as a general means because there are no viable treatment technologies or recycling methods found.

[0006]

The object of the present invention is to provide an FR
As a means to promote material recycling of P molded products,
An object of the present invention is to provide an inexpensive panel excellent in surface design and excellent in soundproofing, strength, and lightness, particularly a panel useful as a soundproofing panel and a wall panel.

[0007]

Means for Solving the Problems As a result of intensive studies, the present inventors have found that a mixture of a coarsely crushed waste FRP molded product and a thermosetting resin is consolidated and hardened to a specific density core layer (B). In addition, the surface layer (A) formed by consolidating and hardening the finely crushed waste FRP molded product with a thermosetting resin on top of it can be effectively used as an excellent panel by sandwich press molding. And completed the present invention.

That is, the present invention provides a panel comprising a surface layer (A), a core material layer (B), and a surface layer (A) from above, wherein the surface layer (A) heats finely crushed FRP molded products. The core material layer (B) is a layer obtained by consolidating the roughly crushed FRP molded product with a thermosetting resin, and has a density of 0.8 to There is provided a panel characterized by 1.4 g / cm ³ .

[0009]

BEST MODE FOR CARRYING OUT THE INVENTION The FRP molded product used for the surface layer (A) and the core layer (B) of the present invention is made of a radical curable thermosetting resin such as an unsaturated polyester resin, a vinyl ester resin or an acrylic resin. Resin, a filler made of fiber reinforcement such as glass fiber and calcium carbonate, a polymerization initiator,
It is a waste product and a recovered product of a molded product obtained by molding a molding material containing a curing accelerator by a known molding method. Preferably SM
This is a general-purpose molded product obtained by molding a C molding material or a BMC molding material by a normal press molding method. Preferably, it is a collected waste of an unsaturated polyester resin molded article. Examples of such molded articles include housing members such as bathtubs, bathroom panels, waterproof pans, vanities, washbasins, kitchen counters, septic tanks, etc., industrial members such as pipes and water tanks, various electric components, ships, Examples include small boats, automobile parts, helmets, mannequins, chairs, unit baths, system kitchens, and the like. The term "waste" as used herein includes not only used recovered materials but also defective products at the time of molding or scrap materials generated in the process.

FRP used in the surface layer (A) of the present invention
It is not necessary to separate composites such as glass fibers from the finely crushed molded product. The particle size of the finely crushed product is preferably 0.1.
It is less than 1 mm, particularly preferably 0.001 to 0.09 mm. The bulk density of the surface layer (A), which is a cured product of the finely crushed product and the thermosetting resin, is preferably 0.5 to 0.9 g /
cm ^3. More preferably, it is 0.6 to 0.8 g / cm ³ . The mixing ratio of the finely crushed material forming the surface layer (A) and the thermosetting resin is preferably 70 to 80% by weight of the finely crushed material and 20 to 30% by weight of the thermosetting resin.

FRP used in the core layer (B) of the present invention
The roughly crushed product of the molded product is preferably 2-1 to sieved at the time of crushing.
0mm mesh, more preferably 2-4
mm. The average diameter is preferably 0.1
１５15 mm. The average diameter is preferably from 2 to 9 mm, particularly preferably from 4 to 7 mm. In the core layer (B), the coarsely crushed material is heat-pressed with a thermosetting resin to form a core material layer (B) which is a cured product. The density of the core material layer (B) is as follows. Preferably, it is 0.8 to 1.4 g / cm ³ , more preferably 0.9 to 1.3 g / cm ³ . The mixing ratio of the coarsely crushed material forming the core material layer (B) and the thermosetting resin is preferably 75 to 90% by weight of the coarsely crushed material and 10 to 2% of the thermosetting resin.
5% by weight.

The method for producing the crushed FRP molded product may be any method, but it is preferable to use a method capable of producing more inexpensive crushed pieces that can be crushed by a commonly used crusher. Various crushers can be used for crushing, and crushed products of various particle sizes can be obtained by combining the shape of the teeth, the number of rotations, the mesh, and the like. Into this crushing machine, the FRP molded product is preferably cut into a length of about 10 to 50 cm and a width of about 10 to 50 cm, and then charged. The crusher is, for example, 2-1
It is preferable that the crusher has a mesh of 0 mm.
It is not preferable to use a crusher having a mesh of less than 2 mm, because the efficiency of coarse crushing is low. At that time, it is unnecessary to separate glass fibers from finely crushed materials such as fillers, except in special cases. When obtaining fine crushed material,
After obtaining a coarse crushed material of about 0.5 to 15 mm by primary crushing, fine crushed material can be easily obtained by further secondary crushing. The obtained crushed material can be singly or combined according to the target product, depending on its density and thickness, or mechanical requirements. For example, for the purpose of weight reduction and cost reduction, a relatively large coarse crushed material can be used to use a core material layer having a high bulk density. Since the surface layer (A) of the present invention uses a finely crushed material, it is preferable to overlay this on the core material layer (B) since a panel with a uniform surface can be obtained. These can be easily transferred to the subsequent step of enhancing the surface design.

The thermosetting resin used in the present invention includes, for example, unsaturated polyester resin, vinyl ester resin,
Any one of acrylic resin, epoxy resin and phenol resin or a combination thereof is selected. Preferably, it is an unsaturated polyester resin. This unsaturated polyester resin is a solution of a polymerizable unsaturated monomer such as a styrene monomer of an unsaturated polyester, and when a curing is performed, a radical polymerization initiator and a curing accelerator are added, and the mixture is heated from room temperature to heating. It will cure. As this unsaturated polyester, those widely used can be used.

The surface layer (A) used in the present invention is made of FRP
Instead of a layer obtained by consolidating a finely crushed product of a molded product with a thermosetting resin, one is, for example, a metal plate, a ceramic plate,
It may be replaced with a non-combustible plate such as a gypsum plate, or may be bonded to the surface layer (A).

The surface layer (A) and the core material layer (B) used in the present invention are made of FR for the purpose of improving sound absorption.
For example, glass, glass wool, ceramic granules, or the like may be mixed with the finely or coarsely crushed P molded product and the thermosetting resin. The addition amount is 0 to 20% by weight in the layer.

Surface layer (A) and core material layer used in the present invention
It is preferable that a sheet or a thin plate is interposed between (B) and the above in order to improve soundproofing and sound absorbing properties. Examples of the sheet or thin plate include an aluminum plate, an aluminum foil, and a resin sheet.

According to the method of applying a design to the panel of the present invention, a wet hydraulic transfer method, a dry vacuum lapping method,
Alternatively, a method such as a method of laminating on the surface of a printed design film can be preferably selected. The surface layer (A)
Either of these methods can be used to impart design properties.

In the panel of the present invention, a honeycomb material can be used for the core layer (B) for the purpose of improving the strength or reducing the weight. That is, as a surface layer (A) and a core layer (B) using a honeycomb material from the top, a mixture of a roughly crushed FRP molded product and a thermosetting resin was filled in the cells, and the core layer was cured. (B), a panel comprising a surface layer (A).

The material of the honeycomb material may be any material such as aluminum, nomex, paper, thermoplastic resin or thermosetting resin. The density and cell size of the honeycomb material may be selected in consideration of strength, cost, and the like, but it is preferable to select a larger cell size so that the cells can be easily filled. For the production of panels using honeycomb material, a mixture of a pre-mixed roughly crushed unsaturated polyester FRP molded product and a thermosetting resin is uniformly filled in a honeycomb material cell and used as a surface layer (A). For example, a method of laminating a metal plate such as an aluminum plate, a ceramic board, or the like, or stacking an aluminum plate, an aluminum foil or a resin sheet on the surface of a core material layer (B) made of a honeycomb, and disintegrating the finely crushed material with a thermosetting resin By forming the surface layer (A) composed of a cured product obtained by consolidation in step (a), a panel having high strength, light weight and a uniform surface can be obtained.

The production of a mixture of a finely crushed or coarsely crushed FRP molded article and a thermosetting resin for forming the surface layer (A) and the core layer (B) of the present invention is generally used. The mixture can be easily and homogeneously mixed with a mixer, and a mixture can be obtained. This mixture can be used as an SMC molding material or BM with reference to an industrially-produced SMC molding material production method.
It is also possible to use a sheet or bulk material such as a C molding material. To press form this mixture,
This is very effective because it leads to a reduction in the time for filling the mold. When the mixture is used as an SMC material or a BMC material, a colorant, a flame retardant, or other additives such as an inorganic filler can be added for the purpose of coloring or improving the flame retardancy. These additives can be used for the purpose of obtaining required physical properties.

In the panel manufacturing method of the present invention, a thermosetting resin, preferably an unsaturated polyester resin, and a finely crushed or coarsely crushed material are mixed in advance, and first, a surface layer (A) is formed on a mold. The mixture of the finely crushed material and the thermosetting resin is filled, and then the mixture of the coarsely crushed material and the thermosetting resin is filled into the core material layer (B), and the surface layer (A) is formed. A panel is formed by filling a mixture of a finely crushed material and a thermosetting resin, closing a mold, heating, press-molding, and curing. Molding conditions are preferably mold temperature: 100 to 150 ° C, pressure: 1
５5 kg / cm ² . The density of the panel is preferably 0.9
１1.3 g / cm ³ .

The panel of the present invention can be manufactured in various sizes according to the intended use. The panel of the present invention has a width of 1.2 m even when using a honeycomb material.
It can be easily manufactured with an X length of about 2.5 m. Its size is preferably: width: 1000 mm × length: 20
00 mm × thickness: 20 to 40 mm. Further, by further cutting the panel, a small panel can be manufactured.

The panel of the present invention is preferably used as a soundproof material, a soundproof panel, or a soundproof wall material. The soundproofing material and the soundproofing panel are used not only for simply reducing the noise of roads and railways, but also as enclosures for construction sites or as simple wall materials. In such applications, it is also important to ensure aesthetics. For that purpose, the surface of the soundproof plate or the soundproof panel obtained by press molding may be designed by various methods.

[0024]

Example 1 A unit bath made of SMC, which had been cut into about 50 cm squares in advance so that it could be put into a crusher, was crushed to obtain crushed pieces that passed through a 4 mm diameter mesh. The average fiber length of crushed pieces is 5mm
Met. Further, the BMC system kitchen was finely pulverized to obtain fine powder of less than 0.1 mm (average particle size: 80 μm). Using "Polylite PM-400" (unsaturated polyester resin, solid content 60% by weight, manufactured by Dainippon Ink and Chemicals, Inc.)
20% by weight of a styrene monomer and 2.5% by weight of Niper NS (a polymerization initiator manufactured by NOF Corporation) were added to this resin. 80/20 (weight ratio) of the coarsely crushed SMC and the unsaturated polyester resin as the core layer (B) and 75/25 (weight) of the finely crushed BMC and the unsaturated polyester resin as the surface layer (A). Ratio),
Each was mixed. The bulk density of the mixture of coarsely crushed SMC / unsaturated polyester resin was about 0.73 g / cc. B
The bulk density of the mixture of MC fines / unsaturated polyester resin was about 0.83 g / cc. A mold is uniformly filled with a mixture of finely crushed BMC / unsaturated polyester resin, and a mixture of coarsely crushed SMC / unsaturated polyester resin is further filled thereon. Of BMC / unsaturated polyester resin mixture and molded at a mold temperature of 140 ° C. for 15 minutes under a pressure of ² kg / cm ² . The density of the molded product was 1.13 g / cc, and a panel having a good surface condition was obtained. The obtained panel plate was processed into a size of 70 mmW × 200 mmL × 20 mmT, and the three-point bending strength (average of n = 5) measured at a span of 16 cm was 6.3 MPa. The sound absorption coefficient of the panel was 0.95 at 400 Hz and 0.75 at 1000 Hz.

Example 2 A finely crushed BMC / resin mixture used in Example 1 was uniformly filled in a mold, and an aluminum sheet having a thickness of 0.1 mm was placed thereon. Furthermore, DC IC Hexell Co., Ltd.
Nomex honeycomb (cell size: 3/16 inch, density: 3.0 lbs / ft3) was loaded, and the inside of the honeycomb cell (honeycomb thickness: 16 mm) was uniformly filled with the SMC crushed fragment / resin mixture. An aluminum sheet having a thickness of 0.1 mm was further placed on the surface, and a BMC fine powder / resin mixture was uniformly filled thereon. A homogeneous panel was obtained by press molding under the same conditions as in Example 1. When a test piece having a size of 100 mm × 20 mmT was prepared and subjected to a compression test, the compression strength was 82.3 MPa. The bending strength of the same test piece as in Example 1 was 1
It was 7.5 MPa.

Example 3 One surface of the soundproof plate prepared in Example 1 was treated with a primer with an epoxy resin and printed by a hydraulic transfer method.
Subsequently, the panel was washed with water, dried, and top-coated with an acrylic urethane resin to obtain a panel having a uniform surface.

[0027]

According to the present invention, as a means for promoting material recycling of FRP molded articles, inexpensive panels having excellent surface design and excellent soundproofing, strength and lightness,
A panel useful as a soundproof panel and a wall panel can be provided. In addition, it is possible to provide an inexpensive and lightweight panel by effectively using crushed materials obtained by crushing used and collected or crushed FRP molded products obtained as process scraps or defective products into various sizes. . The panel of the present invention can use an FRP molded product such as an unsaturated polyester fiber reinforced molded product, which has conventionally been difficult to recycle, and contributes to the promotion of a recycling-oriented society. If it is crushed to an appropriate size after use, there is an advantage that it can be effectively used as it is as a raw material for cement. In addition, it is possible to apply a desired design to the surface, and it is effective not only for providing an aesthetic appearance but also as an advertising medium.

 ──────────────────────────────────────────────────の Continued on the front page (72) Inventor Shigeru Oda 4-32-13 Kugahara, Ota-ku, Tokyo F-term (reference) 2D001 CA01 CB01 CC02 CD03 4F100 AB01C AD00C AK01A AK01B AK01C AK01E AK44A AK44B AK44C AT00D AT00E BA03 BA04 BA05 BA07 BA10A BA10C BA10E DC01B DE01A DE01B DE01C DH02A DH02B DH02C EC04E EH46E GB07 HB31E JA13B JB13A JB13B JB13C JH01 JJ07C JK01 JL03 JL16 JM02D

Claims (7)

[Claims] 1. A surface layer (A), a core material layer (B), and a surface layer from above
In the panel consisting of (A), the surface layer (A) is made of FRP
The core material layer (B) is a layer obtained by consolidating the finely crushed product of the FRP molded product with the thermosetting resin. , Its density is 0.8 ~
A panel characterized by being 1.4 g / cm ³ . 2. The thermosetting resin is an unsaturated polyester resin, and the finely crushed product has an average particle size of less than 0.1 mm;
2. The panel according to claim 1, wherein the coarsely crushed material has an average particle size of 0.1 to 15 mm. 3. A core material layer (B) comprising a honeycomb material and a mixture of a roughly crushed FRP molded product and a thermosetting resin in the honeycomb material cell. Panel described. 4. One of the surface layers (A) is selected from a metal plate, a ceramic plate and a non-combustible plate instead of a layer obtained by consolidating a finely crushed FRP product with a thermosetting resin. The panel according to any one of claims 1 to 3, wherein the panel is formed. 5. The bulk density of the surface layer (A) is from 0.5 to 0.9.
The panel according to claim 1, wherein g / cm ³ is g / cm ³ . 6. A sheet or a thin plate-like material is sandwiched between the surface layer (A) and the core material layer (B).
The panel according to any one of claims 1 to 5. 7. The surface layer (A) is further subjected to printing by a wet hydraulic transfer method or a dry vacuum lapping method on a layer obtained by consolidating finely crushed FRP molded products with a thermosetting resin. The panel according to any one of claims 1 to 6, wherein the panel is obtained by laminating a pre-printed design film.