JPH04209770A - Porous material and its production - Google Patents

Abstract

(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

[Detailed description of the invention] [Industrial application field]

The present invention relates to a porous material suitable for various building materials such as flooring materials, moisture absorbing/releasing wall materials, soundproofing materials, etc. used in places easily exposed to water, and a method for manufacturing the same.

[Conventional technology]

Places that are prone to getting wet, such as bathrooms, galleys, toilets, entrances, balconies, poolside, shower rooms, etc.
In order to prevent slipping due to water, a porous floor material is used, for example, as seen in Japanese Utility Model Publication No. 15308/1983. This porous floor material is made by coating the surface of aggregate such as sand with a particle size of 0.3 mm or more with thermosetting resin, and connecting and solidifying the aggregate at the contact area with this thermosetting resin. Continuous water permeable holes are formed between the aggregates, and these water permeable holes allow water to permeate from the surface to the back surface, thereby preventing slippage when wet.

[Problem to be solved by the invention]

However, in the above-mentioned porous floor material, the diameter of the water permeable pores is large because the aggregates are simply connected and solidified at the contact portions to form gaps between the aggregates. Therefore, there is a problem in that solid impurities enter the water permeation hole together with water, causing clogging and staining. An object of the present invention is to provide a novel porous material and its production that can solve the problems of the prior art.

[Means to solve the problem]

In order to achieve such an object, the porous material according to the present invention is a porous material in which fine powder is pressurized and heated through a reactive resin so that its surface becomes substantially smooth, and the surface is A porous material that has minute openings and has pores formed inside of it through which moisture wetting the surface escapes through the openings when pressure is applied to the surface, and the total pore volume is The method for producing a porous material according to the present invention, which is characterized by a porosity of 2% or more, involves adding a reactive resin, which is liquid at the time of mixing, to a fine powder having a particle size of 0.3 mm or less in true volume in advance. After mixing in a ratio of l:l to 20=1 to obtain a powder whose diameter is substantially greater than the particle size of the fine powder and 5n+m or less, this powder is placed on a mold. Spread it all over the
It is characterized by being pressurized and heated through a cushion sheet that can be elastically and/or plastically deformed.

[For production]

For example, when the above porous material is used as a floor material in a place that gets wet with water, such as a bathroom, the surface is smooth, so when you stand barefoot on it, the soles of your feet will adhere smoothly to the floor surface. Even if the surface is wet with water, the water pressed by the sole of the foot escapes into the pores through the openings, so there is no water film between the sole of the foot and the surface of the porous material. Note that since the pores do not reach the back surface, water that has entered the pores does not permeate to the back surface side. Furthermore, since the openings are minute, dirt and the like are prevented from entering the pores through the openings. On the other hand, according to the above manufacturing method, a powder of a predetermined size can be obtained by mixing fine particles of a predetermined particle size and a predetermined amount of reactive resin with respect to the fine particles. can. Then, the powder is spread over a mold, covered with a cushion sheet from above, and molded into a porous material under uniform pressure, leaving fine voids formed between the fine powder. Since this molded body is cured, there is no unevenness in the openings during molding, and a molded body with pores formed on the surface can be molded.

【Example】

The present invention will be explained in detail below with reference to examples thereof. FIG. 1 is an enlarged sectional view of one embodiment of the porous material according to the present invention, viewed obliquely from above. As shown in the figure, this porous material 1 is plate-shaped and has a substantially smooth surface. Moreover, a large number of minute pores 2 are formed inside. Moreover, this pore 2 communicates with the outside via a minute opening 3 on the surface. In the figure, 4 is a fine powder. That is, the pores 2 are formed between the fine powder particles 4 and the fine powder particles 4. The porosity in the present invention is the volume fraction of the total volume of the pores 2 to the apparent volume of the porous material, It is calculated from the pore volume measured according to the measurement range). In other words, if the porosity is less than 2%, there will be few places for water to escape, causing problems with slip resistance when wet.
In the present invention, the content needs to be 2% or more. Also, the diameter is lOI! A preferable ratio of the pores 2 having openings 3 of rn or more is less than 35%, more preferably 30%, as a volume fraction of the total pore volume by the mercury intrusion method.
less than %. That is, more than l10Ir is 35
% or more, problems arise in terms of stain resistance. The porous material according to the present invention is manufactured as follows. ■ A reactive resin that is liquid at room temperature is added to fine powder having a particle size of 0.3 mm (usually the average value) or less in a true volume ratio of 1:1 to 20:l, preferably 1O:3 to 20:1. : Add at a ratio of 1 and mix. Due to mixing, fine powders may be crushed into even finer powders, or due to the physicochemical properties of the interface, such as the viscosity and surface tension of the resin, fine powders and resin may aggregate and become fine powders. The powder will be in the form of agglomerates that are larger than the granules, but by selecting the mixing method, the diameter of the fine powder or granules can be substantially larger than 5 mm (the proportion of the fine granules is 10% by weight or less by pulverization, The mixture is larger than 5 mm (5% by weight) to form a powder. The mixing method includes mixing with various blenders (e.g., Super Mixer, Eirich Mixer (manufactured by Eirich Mixer), etc.), and further using a dispersing machine (e.g., Turbulizer, manufactured by Hosokawa Micron, Dyno Mill, manufactured by Bachoten, etc.). A method using a device that sprays liquid resin onto fine powder and stirs it [for example, a Shugie mixer manufactured by Sugie, various air flow mixers, a Sutter mixer manufactured by Acme, a flow shed mixer manufactured by Kouken Powtex, etc.] etc. Examples of the fine powder include kaolin, clay, silica sand, natural mineral fibers, crushed natural stone powder, mica, glass milled fibers, alumina staple fibers, potassium titanate staple fibers, carbon staple fibers, and whiskers. Any of these can be used alone or in combination. The optimum size and particle size of the fine powder varies depending on the use of the porous material, etc., but the particle size is 300 um or less (although it is preferable that the particle sizes are the same, an average of 300 um or less is acceptable. ) are used. By adjusting the fiber thickness, particle size, and shape of the fine powder and the viscosity of the thermosetting resin, it is possible to adjust the diameter of the surface opening. In addition, reactive resins that are liquid at room temperature, such as
Unsaturated polyester resins, epoxy resins, phenolic resins, furan resins, imide resins, acrylic resins (including room temperature curing reactive resins that do not necessarily require heating)
etc. ■ Spread the obtained powder on the mold. ■ Cover the powder uniformly spread on the mold with a cushion sheet that can be elastically deformed and/or compositionally deformable, apply pressure through the cushion sheet, and heat it, or heat it after shaping by applying pressure. A porous material can be obtained by reaction solidification. The above-mentioned cushion sheets are not particularly limited, but include:
For example, rubber sheets, foam, felt, non-woven fabrics,
Examples include clay-like pastes and composites thereof. (Example 1) Carbon milled fiber (average fiber diameter 30I!) was prepared in advance.
m) Add 2000 parts by weight of an epoxy resin (a mixture of Epicoat 828 manufactured by Yuka Shell Co., Ltd. and an acid anhydride curing agent in equal amounts of epoxy) (bulk volume ratio 1:0.30) to 2000 parts by weight, and add Fuji Powder to 2000 parts by weight. By Spartan re-user,
The powder obtained by mixing and dispersing was spread homogeneously on a mold, shaped with a press molding machine at room temperature through wool felt with a thickness of 20+ nm, and then heated and hardened to obtain a plate-shaped molded product. In addition, the above powder is 50I! 98% of the particles had a particle size of m or more and 2 mm or less. Further, the porosity of the total pore volume was 6%, and the pores of 10 or more were less than 20% of the total pore volume. (Example 2) In advance, 800 parts by weight of vinyl ester resin (manufactured by U-Pica Japan) was added to 4000 parts by weight of crushed marble powder (240 mesh pass).
Parts by weight (bulk volume ratio 1:0.27) were added, mixed with an Eirich mixer (manufactured by Eirich Mixer), and further dispersed with a turbulizer manufactured by Hosokawa Micron to obtain a powder. This powder was spread on a mold, and on top of it, granulated clay paste was spread in two strokes, and the powder was hardened under pressure to obtain a plate-shaped molded product. Incidentally, 98% of the powdered material had a particle size of 100 mm or more and 3 mm or less. Further, the porosity of the total pore volume was 4%, and the pores of 10- or more were less than 10% of the total pore volume. (Example 3) 4000 parts by weight of white mica powder (200 mesh pass) and 1500 parts by weight of unsaturated polyester resin adjusted to 1 poise using styrene monomer (bulk volume ratio 1:o, 2
5) was added, mixed using a flow shed mixer manufactured by Konken Powtex Co., Ltd., spread uniformly on a mold, covered with urethane rubber, pressurized with a press (50 kg/crt), and then heated and cured at 80°C. A plate-shaped molded body was obtained. Further, the porosity of the total pore volume was 4%, and the pores larger than 10jrm were less than 5% of the total pore volume. (Comparative Example 1) The procedure was the same as in Example 1, except that instead of mixing and dispersing with a Spartan Reuser manufactured by Fuji Paudal Co., Ltd., the powder was mixed with an Eirich mixer and 10% of the powder had a diameter of 5 mm or more. A plate-shaped molded body was obtained. (Comparative Example 2) A plate-shaped molded product was obtained in the same manner as in Example 2, except that 20% of the powder was mixed using an Eirich mixer and had a diameter of 5 mm or more. (Comparative Example 3) Instead of mixing with a flow shed mixer manufactured by Kouken Powtex Co., Ltd., it was mixed with an Eirich mixer and a diameter of 5 m was mixed.
A plate-shaped molded product was obtained in the same manner as in Example 3, except that 15% of the powder had a particle size of m or more. (Comparative Example 4) Instead of mixing with a flow shed mixer manufactured by Kouken Powtex, it was mixed with a super mixer after mixing with a kneader, and 35% of the powder had a particle size that was 1/2 that of the original mica powder. A plate-shaped molded body was obtained in the same manner as in Example 3 except for this. (Comparative Example 5) An attempt was made to obtain a molded article in the same manner as in Example 1, except that the wool sheet was not used. However, a uniform molded product could not be obtained. (Conventional Example) As described in Utility Model Publication No. 15308/1983, 0
．． 5 parts by weight of sand with a particle size of 3 mm or more is mixed with 1 part by weight of unsaturated polyester resin, the surface of the sand is coated with the resin, this is placed in a mold, and heated and cured at 80°C to form a plate-shaped molded product ( A water-permeable resin concrete material) was obtained. The molded bodies obtained in Examples 1 to 3, Comparative Examples 1 to 4, and the conventional example, and a glass filter manufactured by Ise Chemicals (microporous glass 1 with a pore size of 0.3 trrn) as a reference example.
mmX 100mmX IOO+nm), the opening diameter, pore volume, stain resistance, and slip resistance were evaluated, and the results are shown in Table 1. The opening diameter is measured by mercury intrusion method, and the evaluation is that if the volume fraction in the total pore volume is 10- or more,
Those with less than 0% are marked ◎, those with 1Oln11 or more of 10% or more and less than 30% are marked with ○, and those with 10trm or more of 30% or more are marked with ×. Regarding the pore volume, those whose porosity of the total pore volume was 2% or more were indicated by ◎, and those whose porosity was less than 2% were indicated by ×. Contamination resistance was tested by dispersing talcum powder (101!m or less) in water (0.2 g/cc) and spraying 50 cc of this liquid on a 10100 mm x 100 test piece at appropriate times.
The evaluation was rated ◎ if talcum powder remained on the surface and could be washed away later, and × if talcum powder leaked from the back side or caused clogging. Regarding the slip resistance, as shown in Figure 2, on the sloped surface of the porous material, a piece of artificial leather (50 nu
nX 30 mm) 5. Using a load of 2 kg, change the inclination of the porous material (molded body) 1, measure the angle θ at which the artificial leather piece starts to slide, and calculate the coefficient of friction (tan θ).
In the evaluation, a coefficient of friction of 0.6 or more was marked ◎, and a coefficient of friction less than 0.6 was marked X. Table 1 As shown in Table 1, Examples 1 to 3 were all good, but Comparative Examples 1 to 4, Conventional Example, and Reference Example were
There were problems with either stain resistance or slip resistance.

【Effect of the invention】

Since the porous material according to the present invention is configured as described above, it is resistant to slipping when wet with water and is resistant to staining. Therefore, it can be effectively used as a flooring material in bathrooms, cooking rooms, toilets, entrances, balconies, poolsides, shower rooms, etc. In addition, since the surface has pores, it is suitable not only for flooring materials but also for various building materials such as moisture-absorbing wall materials and soundproofing materials. On the other hand, according to the method for producing a porous material according to the present invention,
The above porous material can be manufactured with high precision.

[Brief explanation of the drawing]

FIG. 1 is an enlarged cross-sectional perspective view of one embodiment of the porous material according to the present invention, and FIG. 2 is an explanatory diagram illustrating a slip resistance test. 1... Porous material 2... Pores 3... Openings 4... Fine powder and granules

Claims (2)

[Claims] (1) A fine powder material is pressurized and heated through a reactive resin so that its surface becomes approximately smooth, and the surface has fine openings, and when pressure is applied to the surface, the surface A porous material having pores formed therein through which water wetting the water escapes through the openings, the porous material having a porosity of 2% or more of the total pore volume. . (2) In obtaining the porous material according to claim 1,
A reactive resin that is liquid at the time of mixing is mixed in advance with fine powder particles with a particle size of 0.3 mm or less at a true volume ratio in the range of 1:1 to 20:1, and the diameter is substantially reduced to the size of the particles of the fine powder particles. After obtaining a powder whose diameter is greater than or equal to 5 mm, this powder is spread over a mold and pressurized and heated through a cushion sheet that can be elastically deformed and/or plastically deformed. A method for producing a porous material.