JP2002332367A - Resin board and its manufacturing process - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a resin board manufactured by converting unwanted matters such as remnants of acrylic resin sheets or reinforced plastics into recyclable and valuable matters, and a process for effectively manufacturing this resin board. SOLUTION: In the resin board 1, particulate pulverized substances 2, obtained by finely pulverizing remnants of acrylic resin sheets and/or reinforced plastics, are unified with a resin foam obtained by expanding a resin foam solution 6. The process for manufacturing this resin board 1 comprises the steps wherein remnants of acrylic resin sheets and/or reinforced plastics are finely pulverized until a maximum particle size of <=10 mm is acheived to obtain particulate pulverized substances 2, the particulate pulverized substances 2 are mixed with the resin foam solution 6 to obtain a molding material 12, the resin foam solution 6 is expanded at an expansion ratio of from 1.1 to 30 by inserting the molding material 12 into assembled molds 13 and 14, and releasing the molds 13 and 14.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a resin board in which industrial waste generated in a large amount in a factory or the like is recycled as a valuable resource, and a method for efficiently manufacturing the resin board.

[0002]

2. Description of the Related Art Conventionally, many industrial wastes are generated in factories and the like. For example, in the manufacture of a bathtub, in the step of vacuum forming an acrylic resin sheet, scraps such as an outer peripheral portion of a member for pressing and holding a heated sheet against a mold become unnecessary, and fiber reinforced plastic (ERP). In a molding factory using, scraps such as cut pieces of inspection ports other than products become unnecessary. Unnecessary materials composed of these scraps are discarded as industrial wastes because there is no means for reuse at present. On the other hand, for waste products made of fiber reinforced plastic, various treatment methods are being studied.For example, it is considered that the used product is crushed and mixed with concrete or fiber reinforced plastic for reuse. ing.

[0003]

However, as described above, a large amount of unnecessary materials such as offcuts of an acrylic resin sheet and offcuts of fiber reinforced plastic are generated in a factory.
The fact is that there has been no means to effectively reuse these as valuable resources, and they are disposed of at a large cost as industrial waste.

Accordingly, the present invention has been made in view of the above-mentioned conventional problems, and a resin board which is a valuable material which can effectively reuse unnecessary materials such as acrylic resin sheet scraps and fiber reinforced plastic scraps. It is another object of the present invention to provide a method for efficiently manufacturing the resin board.

[0005]

In order to achieve the above object, a resin board according to a first aspect of the present invention comprises a finely pulverized material obtained by finely pulverizing offcuts of an acrylic resin sheet and / or offcuts of fiber-reinforced plastic. After the substance and the resin foam solution are mixed, the resin foam obtained by foaming the resin foam and the particulate pulverized substance are integrated.

The resin board can be effectively used as a weight-enhancing material which is reduced in weight due to the presence of the resin foam, or requires heat insulation, sound absorption and buoyancy by utilizing the features of the resin foam. It can be effectively used for cavit and casing of various products, and can also be effectively used for various applications that do not require elasticity. In addition, since this resin board uses a material obtained by finely pulverizing offcuts such as an acrylic resin sheet or fiber reinforced plastic as a material, industrial waste can be significantly reduced, and the cost of disposing of these wastes can be reduced. be able to.

[0007] The resin board according to the second invention is characterized in that, after mixing the finely pulverized substance obtained by finely pulverizing offcuts of an acrylic resin sheet and / or offcuts of fiber-reinforced plastic with a resin foam solution, It has a board main body in which a resin foam obtained by foaming a resin foam and a particulate pulverized substance are integrated, and a plate-like reinforcing material bonded to both surfaces of the board main body, respectively. And

In this resin board, in addition to obtaining the same effects as the resin board of the first invention, the resin board has excellent strength due to a pair of reinforcing members sandwiching the board body from both sides. Therefore, for example, it can be very suitably used for a wall material of a bathroom, a front panel of a system kitchen, and the like.

The resin board according to a third aspect of the present invention is characterized in that a resin foam solution is mixed with a particulate pulverized material obtained by finely pulverizing offcuts of an acrylic resin sheet and / or offcuts of fiber reinforced plastic. A board body in which a resin foam obtained by foaming a resin foam and a particulate pulverized substance are integrated; and a board body is combined and fixed to each other so as to form a sealed space inside, and the board body is provided in the sealed space. , And at least a pair of case bodies in which are sealed.

In this resin board, in addition to obtaining the same effects as the resin board of the first invention, the resin board has a higher strength than the resin board of the second invention. Since it can be used as a molding die, the manufacturing process can be simplified and mass production can be performed with high productivity.

[0011] A method for manufacturing a resin board according to a fourth aspect of the present invention is a method for manufacturing a resin board, comprising: finely pulverizing offcuts of an acrylic resin sheet and / or offcuts of fiber-reinforced plastic so that the maximum diameter is 10 mm or less. Obtaining a molding material by mixing the particulate pulverized substance and the resin foam solution, and inserting the molding material into a molded molding die to prepare the resin foam solution from 1.1 to It is characterized by comprising a step of forming a resin foam by foaming at a 30-fold expansion ratio, and a step of releasing the molding die.

According to this method of manufacturing a resin board, a resin board can be manufactured with a high productivity through a very simple series of steps, and the resin boards of various shapes can be manufactured by using a molding die having a required shape. Can be reliably manufactured.

[0013] The method for manufacturing a resin board according to a fifth aspect of the present invention is a method for manufacturing a resin board, which comprises finely pulverizing offcuts of an acrylic resin sheet and / or offcuts of fiber-reinforced plastic so that the maximum diameter is 10 mm or less. Obtaining a molding material by mixing a resin foam solution with the particulate pulverized substance, and combining a pair of case bodies to form a sealed molding space therebetween, Injecting a molding material into the molding space from an injection port of the case, and foaming the resin foam solution to an expansion ratio of 1.1 to 30 times to obtain a resin foam. And

In this method of manufacturing a resin board, a pair of case bodies, which are molding materials, can be fitted and molded while being used as a molding die, so that the steps of assembling and releasing the molding die can be reduced. In addition, since both the case bodies are integrated with the board body in the molding step, the step of bonding the case bodies is not required, and it is possible to produce the case with extremely high productivity. In addition, the obtained resin board is firmly integrated with the board body sealed in both cases, so that the resin board is excellent in robustness.

[0015]

DESCRIPTION OF THE PREFERRED EMBODIMENTS Preferred embodiments of the present invention will be described below with reference to the drawings. FIG. 1 is a longitudinal sectional view schematically showing a resin board 1 according to the first embodiment of the present invention. This resin board 1 is composed of a particulate pulverized substance 2 and a resin foam 3. The particulate pulverized substance 2 is obtained by finely pulverizing various scraps and used products described later with a pulverizer. That is, the particulate pulverized substance 2 is pulverized to a maximum diameter of about 10 mm or less, and the particle diameter of the particulate pulverized substance 2 can be adjusted to a certain degree by classification.

The offcuts used as the raw material of the particulate pulverized substance 2 are scraps generated in a large amount in the step of vacuum forming an acrylic resin sheet, and SMC (sheet molding.
Compounds) These are scraps generated by inspection holes and drilling of system buses manufactured by pressing materials, and scraps generated by cutting system baths and bathtubs manufactured by the hand lay-up method or resin injection method. It has been conventionally discarded as industrial waste.

On the other hand, the resin foam 3 is a polystyrene foam, a polyurethane foam, a polyethylene foam, an unsaturated polyester resin foam, or the like, and a suitable one is selected from these and used according to the application. If the expansion ratio of these resin foams 3 is appropriately selected and set within the range of 1.1 to 30 times according to the intended use, the resin board 1 can be suitably molded. A method for manufacturing the resin board 1 will be described later.

The resin board 1 can be effectively used as a weight-enhancing material which is reduced in weight due to the presence of the resin foam 3, or has a heat insulating property, a sound absorbing property and a buoyancy by utilizing the features of the resin foam 3. The present invention can be effectively used for cavit and casing of various necessary products, and can also be effectively used for various applications that do not require elasticity. In addition, since the resin board 1 uses a material obtained by finely pulverizing offcuts such as an acrylic resin sheet or a fiber reinforced plastic as a material, industrial waste can be significantly reduced, and the cost of disposing of these wastes can be reduced. can do.

FIG. 2 is a longitudinal sectional view schematically showing a resin board 4 according to a second embodiment of the present invention. This resin board 4 has a board body 5 composed of a particulate pulverized substance 2 and a resin foam 3 like the first resin board 1.
The front surface member 7 and the back surface member 8 are joined to both surfaces. As the front surface material 7 and the back surface material 8, it is preferable to use a galvanized steel sheet, a stainless steel plate, an aluminum plate, a cement plate, a resin sheet, or the like.
If properly selected and set within the range of 0.3 to 5 mm, it can be suitably used for various applications. This surface material 7
The back material 8 is bonded to the board body 5 by, for example, an epoxy-based adhesive.

The resin board 4 has the same features as the resin board 1 of the first embodiment, and also has a strength by a front member 7 and a back member 8 which sandwich the board body 5 from both sides. It has become excellent. This allows
This resin board 4 can be very suitably used, for example, as a wall material for a bathroom or a front panel of a system kitchen.

FIG. 3 is a longitudinal sectional view schematically showing a resin board 9 according to a third embodiment of the present invention. This resin board 9 has a board body 5 composed of the particulate pulverized substance 2 and the resin foam 3 similarly to the first resin board 1.
Are enclosed between a front-side case body 10 and a back-side case body 11 each having a box shape with one opening. That is, the front-side case body 10 is overlapped with the outer peripheral surface of the back-side case body 11 so as to be fitted thereon, and a closed space is formed between the two case bodies 10, 11. In the same manner as the resin board 1 according to the first embodiment, a board main body 5 composed of the particulate pulverized substance 2 and the resin foam 3 is sealed.

This resin board has the same features as the resin board 1 of the first embodiment, and also has a higher strength than the resin board 4 of the second embodiment. Therefore, the use can be further expanded, and the pair of case bodies 10 and 11 can be molded as a molding die, so that the production process can be simplified and mass production can be performed with high productivity. it can.

FIGS. 4A to 4C are process diagrams sequentially showing the steps of manufacturing the resin board 1 according to the first embodiment. First, as shown in (a), a particle pulverized substance 2 obtained by finely pulverizing offcuts of an acrylic resin sheet and / or offcuts of fiber-reinforced plastic to a maximum diameter of 10 mm or less with a pulverizer and a polyurethane solution such as a polyurethane solution The resin foam solution 6 is mixed to form a molding material 12. At the time of this mixing, it is preferable to mix the resin foam solution 6 in an amount of 1 to 300 parts by weight with respect to 100 parts by weight of the particulate pulverized substance 2.

Next, as shown in (b), the molding material 12 mixed as described above is injected into a lower mold 13. When the injection of the predetermined amount of the molding material 12 into the lower mold 13 is completed, as shown in FIG.
And the molding material 12 is sealed in the closed molding cavities in both the molds 13 and 14. Subsequently, when the resin foam solution 6 in the molding material 12 is foamed to a predetermined expansion ratio in the molding cavities in the molds 13 and 14, the resin board 1 shown in FIG. 1 is obtained. Is removed by releasing the two molds 13 and 14. The expansion ratio can be set by appropriately selecting from the range of 1.1 to 30 times according to the intended use of the resin board 1.

In this manufacturing method, the resin board 1 can be manufactured with a high productivity through a very simple series of steps, and the lower mold 13 and the upper mold 14 are formed into a required mold shape. By this, resin boards 1 of various shapes
Can be reliably obtained. The resin board 5 according to the second embodiment shown in FIG. 2 has a resin board 1 manufactured through the process of FIG. Can be obtained by bonding with an epoxy-based adhesive.

FIGS. 5A and 5B show the third embodiment shown in FIG.
FIG. 7 is a process chart sequentially showing a process of manufacturing the resin board 9 according to the embodiment. First, as shown in (a), a box-shaped front-side case body 10 having an open bottom surface is fitted over an outer peripheral surface of the box-shaped back-side case body 11 having an open top surface. As shown in b), the two case bodies 10 and 11 are combined in an arrangement forming a closed space therebetween.

The two case bodies 10 combined with the above arrangement,
Numeral 11 is placed on a support 17 and a pressing force is applied from above by a flat plate press 18. Thereby, the closed space becomes a sealed space 19 in the interior between the case bodies 10 and 11. However, the molding space 19 communicates with the outside only through the injection ports 10a, 11a facing the arrangement where the two case bodies 10, 11 match. The supply nozzles 21 of the material supply device 20 are fitted into the two inlets 10 a and 11 a, and the molding material 12 is supplied to the molding space 19 from the material supply device 20 through the supply nozzles 21. This molding material 12 is produced through the steps described with reference to FIG.

Predetermined amount of molding material 1 in molding space 19
When the supply of 2 is completed, the supply nozzle 21 is withdrawn and the injection ports 10a and 11a are sealed. Subsequently, the molding space 19
When the resin foam solution 6 in the molding material 12 in the inside is reacted and foamed to a preset expansion ratio, the board body 5 composed of the resin foam 3 foamed with the resin foam solution 6 and the particulate pulverized substance 2 The two case bodies 10 and 11 are firmly integrated, and the resin board 9 shown in FIG. 3 is obtained. The resin board 9 is taken out from the support 17 after the flat plate press 18 is retracted upward.

According to this manufacturing method, since the pair of case bodies 10 and 11 as the molding material can be fitted and used as a molding die, the steps of assembling and releasing the molding die can be reduced. In addition, since both the case bodies 10 and 11 are integrated with the board body 5 in the molding process, the step of bonding the case bodies 10 and 11 becomes unnecessary, and it is possible to manufacture with extremely high productivity. In addition, the obtained resin board 9 is firmly integrated with the board body 5 sealed in the case bodies 10 and 11, so that the resin board 9 is excellent in robustness.

[0030]

As described above, according to the resin board of the present invention, since the resin foam obtained by foaming the resin foam and the particulate pulverized material are integrated, the resin foam Can effectively be used as a weight-enhancing material due to the presence of a resin, or it can be used effectively for various products requiring heat insulation, sound absorption and buoyancy by taking advantage of the characteristics of resin foam. Can be used,
Furthermore, it can be effectively used for various applications that do not require elasticity. In addition, since this resin board uses a material obtained by finely pulverizing offcuts such as an acrylic resin sheet or fiber reinforced plastic as a material, industrial waste can be significantly reduced, and the cost of disposing of these wastes can be reduced. be able to. Furthermore, if a pair of reinforcing materials are joined to both sides of the board main body, or the board main body is sealed in the pair of cases, the strength can be improved.

According to the resin board manufacturing method of the present invention, a resin board can be manufactured with high productivity through a very simple series of steps, and by using a molding die having a required shape, Resin boards of various shapes can be reliably manufactured. Furthermore, if a pair of case bodies are combined so as to form a sealed molding space therebetween, and a molding material is injected into the molding space, the pair of case bodies are fitted together to form a molding. Since it can be molded while using it as a mold, the mold assembling and releasing steps can be reduced. In addition, both cases are integrated with the board body during the molding process, eliminating the need for a case body bonding step. , And can be manufactured with extremely high productivity. In addition, the obtained resin board is firmly integrated with the board body sealed in both cases, so that the resin board is excellent in robustness.

[Brief description of the drawings]

FIG. 1 is a longitudinal sectional view schematically showing a resin board according to a first embodiment of the present invention.

FIG. 2 is a longitudinal sectional view schematically showing a resin board according to a second embodiment of the present invention.

FIG. 3 is a longitudinal sectional view schematically showing a resin board according to a third embodiment of the present invention.

FIGS. 4A to 4C are process diagrams sequentially illustrating a process of manufacturing the resin board according to the first embodiment.

FIGS. 5A and 5B are process diagrams sequentially showing a process of manufacturing a resin board according to a third embodiment.

[Explanation of symbols]

 1, 4, 9 Resin board 2 Particulate pulverized substance 3 Resin foam 5 Board body 6 Resin foam solution 7 Surface material (reinforcing material) 8 Back material (reinforcing material) 10, 11 Case body 12 Molding material 13, 14 Gold Mold 19 Molding space

──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. ⁷ Identification symbol FI Theme coat ゛ (Reference) B29K 105: 26 B29K 105: 26 B29L 31:10 B29L 31:10 C08L 101: 00 C08L 101: 00 (72) Inventor Hiroaki Tateishi 3-134 Akatsuki-cho, Seto-shi, Aichi Fate term of Tateishi Sangyo Co., Ltd. (reference) 4F074 AA17 AA32 AA46 AA69 AA78 CA48 CA49 DA02 DA20 DA32 DA57 4F100 AB03A AB03C AB04A AB04C AB10A AB10C AB18A AB18C AK01A AK00A AK00A BA03 BA06 DE01B DH02B DJ04B EH71A EH71C GB07 JK20A JK20C JL00 JL02 JL16 JL16B 4F204 AA04 AA13 AA41 AA42 AA50 AB19 AG02 AG20 AH48 EA01 EA04 EB01 EF02 EF51 EL06

Claims (5)

[Claims] A resin obtained by mixing a resin foam solution with a particulate pulverized material obtained by finely pulverizing offcuts of an acrylic resin sheet and / or offcuts of fiber-reinforced plastic, and then foaming the resin foam. A resin board comprising a foam and a particulate pulverized substance integrated with each other. 2. A resin obtained by mixing a particulate material obtained by finely pulverizing offcuts of an acrylic resin sheet and / or offcuts of fiber-reinforced plastic with a resin foam solution and then foaming the resin foam. A resin board comprising: a board main body in which a foam and a particulate pulverized substance are integrated; and a plate-like reinforcing material bonded to both sides of the board main body. 3. A resin obtained by mixing a resin foam solution with a particulate pulverized substance obtained by finely pulverizing offcuts of an acrylic resin sheet and / or offcuts of fiber-reinforced plastic, and then foaming the resin foam. A board body in which a foam and a particulate pulverized substance are integrated, and at least a pair of cases in which the board body is combined and fixed to each other to form a sealed space inside, and the board body is sealed in the sealed space. A resin board having a body. 4. A step of finely pulverizing offcuts of an acrylic resin sheet and / or offcuts of fiber-reinforced plastic so as to have a maximum diameter of 10 mm or less to obtain a pulverized material, Mixing the resin foam solution to obtain a molding material; inserting the molding material into a molded mold, foaming the resin foam solution to an expansion ratio of 1.1 to 30 times, and foaming the resin. A method for manufacturing a resin board, comprising: a step of forming a body; and a step of releasing the molding die. 5. A step of finely pulverizing offcuts of an acrylic resin sheet and / or offcuts of fiber-reinforced plastic to a maximum diameter of 10 mm or less to obtain a pulverized material; Mixing a resin foam solution to obtain a molding material; combining a pair of case bodies so as to form a sealed molding space therebetween; and forming the molding material through an injection port of the case. And injecting the resin foam solution into a foam at a foaming ratio of 1.1 to 30 times to form a resin foam.