JPH03100029A - Porous board and its preparation - Google Patents

Abstract

PURPOSE:To prepare a porous board, stain-resistant and finely cell-structured, by mixing an aggregate comprising fine particles with a thermosetting resin, pouring the mixture into a mold, placing an absorbent material on the mixture's surface not in contact with the mold, covering the absorbent material and the mold with a sheet, evacuating air present between the sheet and the mold to remove an excess resin, and thermally curing the mixture. CONSTITUTION:An aggregate comprising fine particles (e.g. wollastonite) is mixed with a thermosetting resin (e.g. an unsatd. polyester resin) to give a pasty mixture, which is poured into a mold; an absorbent material; (e.g. an absorbent paper) on the mixture's surface not in contact with the mold; the absorbent material and the mold are covered with a sheet; air between the mold and the sheet is evacuated with a vacuum pump to cause the absorbent material to absorb an excess resin and thereby remove it from the mixture; and the mixture is thermally cured to give a porous board. The resulting board is useful as a material for floor, wall, etc.

Description

DETAILED DESCRIPTION OF THE INVENTION (Industrial Application Field) The present invention relates to a porous board having microscopic voids therein, which is used for flooring, walling, and the like.

(Conventional technology) Conventionally, resin concrete flooring materials have been used in which the surface of aggregates such as sand is coated with thermosetting resin, which is connected and solidified at the contact areas of the aggregates to form gaps and permeable holes between the aggregates. It is commonly used for pavements, etc. Flooring materials with such a structure allow water to pass through from the surface to the back side, thereby preventing slipping when wet.

(Problem to be solved by the invention!) However, in the above-mentioned prior art, the pore diameter is 0.1 to 0.
Since it is large at 3 on, it has the disadvantage that dust can easily flow in and get dirty.

It is an object of the present invention to solve the problems of the prior art described above and to provide a porous plate having fine voids and not easily soiled.

(Means for solving the problems) The present invention has the following features:1. A paste mixture made by kneading thermosetting resin into aggregate made of fine powder is injected into a mold, excess resin components are removed using an absorbent material, and after the absorbent material is removed, heating is performed. 2. A porous plate formed by hardening. A paste mixture made by kneading thermosetting resin into aggregate made of fine powder is injected into a mold, excess resin components are removed with an absorbent material, and then heated together with the absorbent material. 3. A porous plate formed by hardening. @A paste mixture made by kneading thermosetting resin into aggregate made of fine powder and granules is injected into a mold,
It is characterized by laying an absorbent material on the surface not in contact with the mold, covering the absorbent material with a sheet together with the mold, reducing the pressure inside to remove excess resin components, and then heating and curing. The gist of this paper is a method for manufacturing a porous plate.

As the aggregate used in the present invention, milled fibers, alumina short fibers, potassium titanate short fibers, carbon fibers, whiskers, wollastonite, etc. are preferably used.

As the thermosetting resin used in the present invention, unsaturated polyester resins, epoxy resins, phenolic resins, etc. are preferably used, and they are usually made with a low viscosity by adding an appropriate solvent such as styrene monomer that does not interfere with curing. It is desirable to adjust to

In the present invention, the amount of thermosetting resin kneaded into the aggregate is preferably 25 to 75% by weight.

The pore diameter of the porous plate can be adjusted depending on the particle size and shape of the fine powder and the viscosity of the resin.

In order to remove excess resin components in the present invention, on the side of the mixture injected into the mold that is not in contact with the mold,
It is sufficient to press an absorbent material such as absorbent paper, non-woven fabric, porous powder such as sepiolite, zeolite, etc., usually 60 kg/c.
Press with a pressure of d or more. Also, if you do not press,
By making the viscosity of the resin as low as 1-voice or less and setting the mold so that the surface of the mold faces downward so that the mixture is suspended in the air, gravity will work on the injected material and the time required will be shortened. preferable.

Incidentally, the absorbent material may be removed after molding, or alternatively, in accordance with the second aspect of the present invention.
The porous plate may be used as it is as a backing material or reinforcing material, as in the case of the latter, it is possible to reduce the thickness of the porous plate.

Furthermore, as in the third aspect of the present invention, the outermost periphery of the mold is covered with a vacuum sheet, the surrounding area is sealed with adhesive tape, etc., and the air between the mold and the sheet is decompressed with a vacuum pump. good. By doing this, it is possible to increase the number of holes (increasing the volume of micropores by increasing the absorption effect of excess resin), reduce the loss of pressure transmission during pressing, and make it possible to fill the mixture with high density. At times, the thermosetting resin can be uniformly and completely cured by blocking oxygen.

Next, an example of a general method for manufacturing the porous plate according to the first or second aspect of the present invention will be described.

First, a liquid thermosetting resin is added to an aggregate made of fine powder and granules and kneaded to form a paste, and the mixture is homogeneously injected into a mold. An absorbent material is pressed against the surface of the mixture that is not in contact with the mold, excess resin components are removed, and the mixture is heated and cured.

(Function) The porous plate according to 1 or 2 of the present invention is produced by injecting a paste-like mixture into a mold by kneading a thermosetting resin into aggregate made of fine powder, and removing excess Since the resin component is removed with an absorbent and the material is heated and hardened, fine voids with uniform pore diameters are formed between the fine powder aggregates, which in turn increases the specific surface area of the plate surface. .

Furthermore, in the method for manufacturing a three-porous plate of the present invention, when removing excess resin components from the mixture injected into the mold,
Absorbing material is installed and the pressure is reduced, which improves the absorption efficiency of excess resin.

(Examples) Next, the present invention will be specifically explained by examples, but the present invention is not limited by these examples.

Example 1 70 parts by weight of wollastonite with a particle size of 400 mesh,
30 parts by weight of an unsaturated polyester resin whose viscosity was adjusted to 2 poise using styrene monomer was added and kneaded to form a paste, and the mixture was homogeneously poured into a mold. Next, absorbent paper is pressed against the surface of the mixture injected into the mold that is not in contact with the mold (open surface) to remove excess resin components, and the mixture is placed in a curing oven and heated at 80°C. After curing, a porous plate was obtained.

Example 2 35 parts by weight of an epoxy resin was added to 65 parts by weight of short potassium titanate fibers having a particle size of 300 mesh, and the mixture was kneaded to form a paste, and the mixture was uniformly poured into a mold. Next, sepiolite is pressed against the side of the mixture injected into the mold that is not in contact with the mold, excess resin components are removed, and the mixture is heated and hardened at 100°C in a curing furnace to form a porous material. A sex plate was obtained.

Example 3 70 parts by weight of wollastonite with a particle size of 400 mensius,
33 parts by weight of an unsaturated polyester resin whose viscosity was adjusted to 2 poise using styrene monomer was added and kneaded to form a paste, and the mixture was homogeneously poured into a mold. Next, absorbent paper is pressed against the surface of the mixture injected into the mold that is not in contact with the mold, and the outside of the mixture is further covered with a vacuum sheet together with the mold to seal the surroundings.
The pressure between the mold and the sheet was reduced using a vacuum pump to remove excess resin components, and the mixture was placed in a curing furnace and cured by heating at 80°C to obtain a porous plate.

Example 4 40 parts by weight of an epoxy resin was added to 65 parts by weight of short potassium titanate fibers having a particle size of 300 mesh, and the mixture was kneaded to form a paste, and the mixture was uniformly poured into a mold.

Next, sepiolite is pressed against the side of the mixture injected into the mold that is not in contact with the mold, and the outside is further covered with a vacuum sheet along with the mold to seal the periphery, and the gap between the mold and the sheet is sealed. Reduce the pressure with a vacuum pump and reduce the pressure to 60 kg.
After pressing at a pressure of /cffl to remove excess resin components, the mixture was placed in a curing furnace and cured by heating at 100°C to obtain a porous plate.

Example 5 30 parts by weight of an unsaturated polyester resin whose viscosity was adjusted to 2 voids using a styrene monomer was added to 65 parts by weight of potassium titanate short fibers having a particle size of 300 mesh, and the mixture was kneaded to form a paste. , homogeneously poured into the mold. Next, absorbent paper is pressed against the side of the mixture injected into the mold that is not in contact with the mold, excess resin components are removed, and the mixture is placed in a curing oven together with the absorbent paper and heated and cured at 80°C. Finally, a porous plate was obtained.

Example 6 67 parts by weight of wollastonite with a particle size of 400 mesh,
A mixture of 40 parts of epoxy resin added and kneaded into a paste was homogeneously poured into a mold. Next, sepiolite was pressed against the side of the mixture injected into the mold that was not in contact with the mold, and after pressing at a pressure of 60 kg/cJ to remove excess resin components, the mixture was put into a curing furnace together with sepiolite. A porous plate was obtained by heating and curing at 100°C.

Example 7 Alumina short grain size 200 mesh! ! To 65 parts by weight of 1I, 35 parts by weight of an unsaturated polyester resin whose viscosity was adjusted to 1 poise using a styrene monomer was added, and the mixture was kneaded to form a paste, and the mixture was uniformly injected into a mold. Next, a glass chopped strand cloak was pressed against the surface of the mixture injected into the mold that was not in contact with the mold, and the excess resin component was removed by pressing at a pressure of sokg/d. Place it in a curing oven with the glass chopped strand mat and heat it to harden at 80°C.
A porous plate was obtained.

Example 8 40 parts by weight of an unsaturated polyester resin whose viscosity was adjusted to 2 voids using a styrene monomer was added to 60 parts by weight of alumina short fibers having a particle size of 200 mesh, and the mixture was kneaded to form a paste, and the mixture was molded. It was poured homogeneously into the mold.

Next, absorbent paper is pressed against the side of the mixture injected into the mold that is not in contact with the mold, and the outside is further covered with a vacuum sheet to seal the periphery, and a vacuum is created between the mold and the sheet. After reducing the pressure with a pump to remove excess resin components, the mixture was placed in a curing oven together with absorbent paper and heated and cured at 80'C to obtain a porous plate.

Example 9 45 parts by weight of an epoxy resin was added to 55 parts by weight of short potassium titanate fibers having a particle size of 300 mesh, and the mixture was kneaded to form a paste, and the mixture was uniformly poured into a mold.

Next, sepiolite is pressed against the side of the mixture injected into the mold that is not in contact with the mold, and the outside is further covered with a vacuum sheet along with the mold to seal the periphery, and the gap between the mold and the sheet is sealed. The pressure was reduced using a vacuum pump to remove excess resin components, and the mixture was placed in a curing furnace together with sepiolite and cured by heating at 100°C to obtain a porous plate.

Example 10 65 parts by weight of wollastonite with a particle size of 400 mesh,
35 parts by weight of an unsaturated polyester resin whose viscosity had been adjusted to 1 poise using styrene monomer was added and kneaded to form a paste, and the mixture was homogeneously poured into a mold. Next, a glass tin strand cloak is pressed against the surface of the mixture injected into the mold that is not in contact with the mold, and the outside of the cape is further covered with a vacuum sheet along with the mold to seal the periphery, and the mold is removed. After reducing the pressure between the strand and the sheet using a vacuum pump to remove excess resin components, the glass chopped strand mat was placed in a curing oven for 80 minutes.
A porous plate was obtained by heating and curing at 'C.

Comparative Example 1 A porous plate was obtained in the same manner as in Example 1, except that absorbent paper was not pressed against the surface of the mixture injected into the mold that was not in contact with the mold.

Comparative Example 2 A porous plate was obtained in the same manner as in Example 2, except that sepiolite was not pressed against the surface of the mixture injected into the mold that was not in contact with the mold.

Comparative Example 3 A porous plate was obtained in the same manner as in Example 3, except that absorbent paper was not pressed against the surface of the mixture injected into the mold that was not in contact with the mold.

Comparative Example 4 A porous plate was obtained in the same manner as in Example 4, except that sepiolite was not pressed against the surface of the mixture injected into the mold that was not in contact with the mold.

Comparative Example 5 A porous plate material was obtained in the same manner as in Example 5, except that absorbent paper was not pressed against the surface of the mixture injected into the mold that was not in contact with the mold.

Comparative Example 6 A porous plate was obtained as in Example 6, except that sepiolite was not pressed against the surface of the mixture injected into the mold that was not in contact with the mold. Comparative Example 7 Injected into the mold. A porous plate was obtained in the same manner as in Example 7, except that the glass chopped strand mat was not pressed against the surface of the mixture that was not in contact with the mold.

Comparative Example 8 A porous plate was obtained in the same manner as in Example 8, except that absorbent paper was not pressed against the surface of the mixture injected into the mold that was not in contact with the mold.

Comparative Example 9 A porous plate was obtained in the same manner as in Example 9, except that sepiolite was not pressed against the surface of the mixture injected into the mold that was not in contact with the mold.

Comparative Example 10 A porous plate was obtained in the same manner as in Example 10, except that the glass chopped strand mat was not pressed against the surface of the mixture injected into the mold that was not in contact with the mold.

Comparative Example 11 5 parts by weight of sand with a particle size of 0.3 an or more was mixed with 1 part by weight of an unsaturated polyester resin of 10 to 15 poise, poured into a mold, placed in a curing furnace, and heated and cured at 80°C. A porous plate was obtained.

Comparative Example 12 Microporous glass (manufactured by Ise Kagaku Co., Ltd.) with a pore diameter of 0.3 μm was used as a glass filter having a fine uniform pore diameter.

For each of the above Examples and Comparative Examples, measurement of pore diameter (percentage of pores with a pore diameter of 1μ or more in the total pores) and pore volume (cc/g) by mercury intrusion method, talc with a particle size of 10μ or less A stain resistance test was conducted in which an aqueous solution containing 0.2 g/cc of powder was dispersed on a 100mm x 100mm test piece to see if talcum powder remained on the surface. A slip resistance test was conducted to measure the coefficient of friction (tanθ) with an artificial leather test piece, and the results are shown in Table 1.

Table 1 Umbrella 1: Same as Examples 1 to 10 (effects of the invention) The porous plate of the present invention 1 or 2 is made by kneading a thermosetting resin into aggregate made of fine powder and making a paste. The mixture is injected into a mold, the excess resin component is removed with an absorbent material, and the mixture is heated and cured, so that fine pores with uniform diameters are formed on the surface of the porous plate. The specific surface area has increased, making it less slippery and stain-resistant even when wet.

Therefore, it can be suitably used for flooring materials, moisture absorbing/releasing wall materials, soundproofing materials, etc. for bathrooms, cooking rooms, toilets, entrances, balconies, poolsides, shower rooms, etc.

In the porous plate according to the second aspect of the present invention, since the absorbent material is used as a backing material or a reinforcing material, the porous plate is made thinner.
It can be provided at low cost.

The method for producing a porous plate according to the third aspect of the present invention is to inject a paste mixture made by kneading a thermosetting resin into aggregate made of fine powder into a mold and contact the mold. An absorbent material is placed on the surface that is not covered, and the absorbent material is covered with a sheet along with the mold, and the interior is depressurized to remove excess resin components, and then heated and cured, so that the absorption effect of excess resin components is improved. This increases the volume of micropores, reduces pressure transmission loss during pressing, allows the mixture to be densely packed, and blocks oxygen during curing to evenly and completely coat the thermosetting resin. It can be hardened.

Claims (1)

[Scope of Claims] 1. A paste mixture made by kneading a thermosetting resin into aggregate made of fine powder is injected into a mold, and excess resin components are removed with an absorbent; A porous plate characterized in that it is made by heating and curing after removing the absorbent material. 2. A paste mixture made by kneading a thermosetting resin into aggregate made of fine powder is injected into a mold, excess resin components are removed with an absorbent material, and then the absorbent material A porous plate characterized by being formed by heating and curing the same. 3. A paste-like mixture made by kneading thermosetting resin into aggregate made of fine powder is injected into a mold, and an absorbent material is laid on the surface that is not in contact with the mold. A method for manufacturing a porous plate, which comprises covering the material together with a mold with a sheet, reducing the pressure inside to remove excess resin components, and then curing by heating.