JPS63288977A - Resin molding formed with open cells and its production - Google Patents

Abstract

PURPOSE:To form a high-strength resin molding formed with open cells by polymerizing and curing a liquid resin essentially composed of a synthetic resin consisting of plural kinds of inorg. fillers which are different in grain size from each other as well as volatile matter and synthetic resin. CONSTITUTION:This resin molding formed with the open cells is formed by distributing and incorporating plural kinds of the inorg. fillers which are different in grain size from each other into a base material essentially consisting of the synthetic resin into the most densely packed state so that the open cells are formed along the particles of the inorg. fillers. This molding can be produced by the following method: The liquid resin essentially composed of the synthetic resin incorporated therein with plural kinds of the inorg. fillers which are different in grain size from each other and the volatile matter is prepd. The above-mentioned volatile matter is evaporated away to convert the traces of the removal to the open cells at the time of forming the cured body by polymerizing and curing the above-mentioned liquid resin. The synthetic resin is exemplified by an epoxy resin, polyester resin, polyolefin resin, PVC resin, etc., the volatile matter is exemplified by low mol.wt. materials such as alcohols and glycols and the inorg. fillers are exemplified by quartz, alumina, etc.

Description

DETAILED DESCRIPTION OF THE INVENTION [Industrial Field of Application] The present invention relates to a continuous pore-forming resin molded article that has continuous pores evenly distributed and has excellent strength, and a method for producing the same.

[Conventional technology]

Conventionally, pore-forming resin molded products have been produced using two methods: (1) a foaming method in which a blowing agent is added to a synthetic resin resin liquid (undiluted solution) and pores are formed by foaming the foaming agent, and (2) a method in which pores are formed by mixing the stock solution and an inorganic filler. It is manufactured by a method such as a method in which a large amount of inorganic filler is added and pores are formed in the gaps between particles of the inorganic filler to obtain a porous body.

[Problem that the invention seeks to solve]

However, the porous body formed by the above method (①)
Since the generated pores are due to foaming by the foaming agent, the pore size of the porous body is uneven and the strength is low, and a skin layer of resin is formed on the surface of the porous body during manufacturing. There is a problem in that the pores in the skin layer become finer or do not form communicating pores that communicate with the outside. In addition, when manufacturing a porous body by increasing the amount of inorganic filler as in method The disadvantage is that the surface side becomes smaller). In addition, in this case, a considerable amount of air is likely to be drawn into the molded product during mixing, making it difficult to obtain a uniform, highly dense porous body. As described above, a high-strength porous body with water permeability could not be obtained using conventional methods.

The present invention was made in view of the above circumstances, and an object of the present invention is to provide a resin molded product with continuous pores that is excellent in strength and a method for manufacturing the same.

[Means for solving problems]

In order to achieve the above object, the present invention contains multiple types of inorganic fillers having mutually different particle sizes distributed in a close-packed state in a base material mainly made of synthetic resin, and The first aspect is a resin molded product with continuous pores formed in it, which is mainly made of synthetic resin containing multiple types of inorganic fillers and volatile substances with mutually different particle sizes. A continuous pore-forming resin molded article, characterized in that when a resin liquid is prepared, and the resin liquid is polymerized and cured to form a cured body, the volatile substances are continuously removed and the traces of the removal are formed into continuous pores. The second gist is the manufacturing method.

That is, in order to achieve the above object, the present inventor has conducted research focusing on the particle size of the agent used for pore formation and the inorganic filler used. The present inventors have discovered that when a volatile substance is used as a pore-forming agent, a high-strength continuous pore-forming resin molded article can be obtained, and the present invention has been achieved.

The continuous pore-forming resin molded article of the present invention is obtained using a plurality of types of inorganic fillers having mutually different particle sizes, a volatile substance, and a resin liquid mainly composed of synthetic resin.

Examples of the synthetic resin include thermosetting resins such as epoxy resins and polyester resins, polyolefin resins such as high-density polyethylene, and thermoplastic resins such as vinyl chloride.

Examples of the volatile substances include low molecular weight substances such as alcohols and glycols.

Further, examples of the inorganic filler include quartz, alumina, etc., and in particular, a plurality of types of fillers having different particle sizes are used. As a combination of multiple types of different particle sizes,
For example, those larger than 100 μm (A), 30~
A mixture of three types: 100 arm (B), 30μ, 1) less than 1 (C'), weight ratio A/B/C = 1/2/1
, also larger than 100 am (A), 30 μm
An example is a combination in which two types of (C) below are mixed at a weight ratio of A/C=1/2, etc. Note that these combinations are not limited.

The continuous pore-forming resin molded article of the present invention is manufactured using the above-mentioned raw materials, and is useful as a mold for products such as concrete and ceramics. Such a resin molded article with continuous pores can be produced, for example, in the following manner. That is, a plurality of types of 81-free fillers and volatile substances with different particle sizes are added to the resin liquid mainly composed of the above synthetic resin, mixed, poured into a predetermined mold, and then left in a semi-cured state. Perform a bubble formation process. The blending amount of each of the above raw materials is 100 parts by weight of the synthetic resin liquid (hereinafter "
(abbreviated as "part"), the inorganic filler is 200 to 800
parts, preferably from 300 to 600 parts, and volatile substances from 10 to 50 parts, preferably from 20 to 30 parts. When performing this bubble formation treatment, if the synthetic resin that is the main component of the base material is a thermosetting resin, heating (over 80°C) by irradiation with electromagnetic waves and far infrared rays, and When the resin is a thermoplastic resin, the bubble forming treatment is performed by heating under reduced pressure using the method described above. During this heating, the volatile substances vaporized and gasified by the heating pass between multiple types of inorganic fillers with different particle sizes, forming uniform and fine continuous pores. Since the inorganic filler is distributed in the base material in a close-packed state, a resin molded article with continuous pores having excellent strength can be obtained. Here, the term "closest packed state" means that 50% by weight or more, preferably 70% by weight or more of the inorganic filler is distributed with the particles closely spaced from each other.

Such a resin molded product with continuous pores is used for the following purposes. For example, in a molding apparatus as shown in FIG. 1, a resin molded article l made of synthetic resin sponge with continuous holes, which is a product of the present invention, is disposed inside an upper frame body 3 having a U-shaped cross section. used as such. A vacuum suction pipe 5 is extended within the molded product 1 for the upper mold.

This vacuum suction pipe 5 is provided with a plurality of openings at predetermined intervals. The end of the vacuum suction pipe 5 is connected to a vacuum suction pump (not shown) via a connecting pipe (not shown), and a shutoff valve is provided in the middle of this connecting pipe. Reference numeral 4 denotes a lower frame body having a U-shaped cross section, and is provided with a molded product 2 for the lower mold similar to the molded product 1 for the upper mold. The molded product 2 is also provided with a vacuum suction vibro having a structure similar to that described above. This vacuum suction vibro is
It is connected to a vacuum pump (not shown) and a compressed air delivery pump (not shown) via a switching valve provided on a connecting pipe (not shown). The upper molds 1, 3 and the lower molds 2, 4 are connected to a conventionally known mold opening/closing device (not shown).
The mold can be opened and closed by moving up and down. Further, a press inlet 9 is formed on the side surface of the lower mold 2.4 for press-fitting the raw material slurry 7 into the molding space created by the molded product 1 and the molded product 2.

In this configuration, the raw material slurry 7 is press-fitted from the press inlet 9 with the mold closed as shown in the figure. At the same time, vacuum suction is performed from the vacuum suction pipe 5 of the upper mold and the vacuum suction vibro of the lower mold, and moisture is discharged to the outside through the communicating holes of the molded products 1.2 of the upper mold and the lower mold. This operation is continued until the molding space is filled with the molded article. Next, when the molded product has sufficient strength, compressed air is discharged from the vacuum suction vibro in the lower mold, and at the same time, the upper mold is moved to the lower mold while continuing suction with the suction pipe 5. (see Figure 2). Thereby, the molded article 8 rises while being adsorbed to the surface of the molded article 1 of the upper mold. Then, in this state, the receiver inserts a plate (not shown) between the upper mold and the lower mold to cut off the vacuum suction of the upper mold. As a result, the molded body 8 separates from the surface of the molded product 1, and the receiver falls into the pan.

In this way, concrete moldings and ceramic molded bodies can be efficiently produced using the product of the present invention, and the product of the present invention is extremely useful as a molding material for these.

(Effects of the Invention) As described above, the present invention produces a cured product by polymerizing and curing a resin liquid mainly composed of a synthetic resin in which multiple types of inorganic fillers and volatile substances having mutually different particle sizes are uniformly distributed. The continuous pore-forming resin molded product is manufactured by continuously heating and removing volatile substances from this cured product and turning the removed residue into pores.The resulting continuous pore-forming resin molded product has high strength and uniformity. Not only does it have fine pores, but the formed pores become continuous pores and have water permeability.Therefore, the continuous pore-forming resin molded product of the present invention is extremely useful as a molding material for concrete products, etc. It is.

Next, the present invention will be explained in detail based on examples.

[Example 1] 600 parts of three types of inorganic fillers (quartz powder) with different particle sizes were added to 100 parts of epoxy resin liquid (weight ratio: 10
0μm 730-100μm / 30μm ＞=1/
2/1) At the same time as blending, 20 parts of ethyl alcohol was blended and mixed, and the mixture was cast into a predetermined mold. Next, this mold together with the mold is heated to harden the resin and at the same time volatilize the ethyl alcohol, producing a molded product 1 having the shape shown in Figure 1.
,2 was obtained. This product showed good performance as a water-permeable type.

[Example 2] 600 parts of two types of inorganic fillers (alumina) with different particle sizes were added to 100 parts of epoxy resin liquid (weight ratio = 10
0 μm</30 μ+n >= 1 /2 ) and 30 parts of ethylene glycol were added and mixed, and the mixture was poured into a predetermined mold. From this point onwards, the same procedure as in Example 1 was carried out to obtain molded article 1.2. This product showed good performance as a water-permeable type.

[Brief explanation of the drawing]

FIG. 1 is a sectional view of a molding apparatus using a molded article according to an embodiment of the present invention as a mold, and FIG. 2 is an explanatory diagram of its operation. 1...Molded product for upper mold 2...Molded product for lower mold 3
．． 4...Frame body 5.6...Vacuum suction vibrator 7...
・Raw material slurry 8... Molded object 9... Pressure port No. 1
Figure 2

Claims (2)

[Claims] (1) Multiple types of inorganic fillers with different particle sizes are distributed and contained in a close-packed state in a base material mainly made of synthetic resin, with communicating pores being formed between the inorganic filler particles. A resin molded product with continuous pores. (2) When preparing a resin liquid mainly composed of synthetic resin containing multiple types of inorganic fillers and volatile substances with mutually different particle sizes, and polymerizing and curing this resin liquid to form a cured body, the above-mentioned A method for manufacturing a resin molded product with continuous pores, characterized by removing volatile substances by volatilization and forming continuous pores in the residue left after the removal.