JP2844845B2 - Synthetic resin top plate and method of manufacturing the same - Google Patents

Description

Description: TECHNICAL FIELD The present invention relates to a novel synthetic resin top plate used for kitchen counters and the like, and a method for producing the same. More specifically, by reinforcing the end of the cut-out opening of the filled synthetic resin top plate having a cut-out hole into which a heating device such as a gas stove is fitted by a specific method, excellent heat resistance and mechanical strength can be obtained. The present invention relates to a synthetic resin top plate and a method for manufacturing the same, which do not have a defect such as a tarak at the corner of the hole even when repeatedly receiving heat history from a heating device such as a gas stove.

[Prior art] Conventionally, as a top plate which is a component member of a counter of a kitchen facility using a heating device such as a gas stove,
Filled synthetic resin top plates are widely used because they are beautiful, clean, durable, lightweight, and easy to process.

In order to make a filled synthetic resin top plate, usually, first, a synthetic resin top plate with a hole formed according to the shape of the heating device is made, and a gas stove,
A method of fitting and installing a heating device such as a hot plate and an oven has been used.

These will be described with reference to the drawings. FIG. 1 is a schematic view of a kitchen counter, in which 1 is a top plate made of a synthetic resin containing a filler, 2 is a back guard which is a rising portion integrally formed with the top plate, and H is fitted into the hole. 2 shows a heating device such as a gas stove, a hot plate, an oven, etc. FIG. 2 (A) is a schematic view of a synthetic resin top plate 1 in which a hole is formed in accordance with the shape of the heating device, 3 is a square hole formed in the top plate, and 3a is a hole in the top plate. Shows the opening of the hole.

A conventional synthetic resin top plate 1 having such a structure.
Is easy to be damaged because the opening 3a is exposed, and cracks are generated at the corners of the hole when used repeatedly, which is not practical. .

The cause of the occurrence of such cracks is considered as follows.
A typical material of the synthetic resin top plate is a mixture of acrylic and aluminum hydroxide. In a top plate formed of such a material, polymer molecules of poly (ethyl methacrylate), which is a main raw material of acrylic resin, are kept firm by intermolecular force at low temperature (normal temperature), and exhibit a glass-like solid state. It is called a glass state (plastic material course [12] acrylic resin,
36-37, by Takashi Asami, published by Nikkan Kogyo Shimbun. When the open end of the hole of the top plastic, which is stable in the glassy state, is heated, the end gradually begins to expand, and strain energy (as compressive stress) is stored inside. When the temperature further rises and reaches the glass transition temperature, it softens and sharply decreases in elastic modulus, that is, becomes rubbery, and the stored strain energy due to thermal expansion is converted into volume expansion. When heating is stopped in a state in which the strain energy is divergent due to such conversion, the phase changes from an expanded rubber state to a glass state with a decrease in temperature, and further a thermal contraction occurs when the temperature further decreases. As a result, strain energy (as tensile stress) is generated inside. Then, when the temperature returns to room temperature, thermal contraction corresponding to the temperature difference between the glass transition temperature and room temperature occurs. And occurs at the end of the hole. Further, when heating and cooling are repeated, accumulation in the inside increases, and when the tensile strength of the material exceeds the tensile strength, cracks occur.

As described above, it is considered that the above-mentioned phenomenon occurred at the end of the hole, and stress concentration at the corner portion was remarkable, and a crack was generated at the corner portion.

In order to cover these drawbacks, it is impossible to prevent the specific phenomena associated with the heating and cooling of the synthetic resin top plate itself, so the idea was to forcibly prevent stress concentration due to the occurrence of strain. Next, it has been considered that an FRP layer having a thermosetting property is attached to the opening 3a of the cutout portion 3.

As a first method for carrying out this, a synthetic resin top plate having a hole to be fitted with a heating device is prepared, and is hardened by heat in advance according to the shape of the edge of the hole at the opening of the opening. Adhesive was used to bond fiber reinforced plastic (abbreviated as FRP) sheets that were manufactured using this method, but it was difficult to manufacture FRP sheets according to the shape of the kiguchi surface, and the kiguchi surface was beautifully flattened. If it is not done, the adhesive layer will have uneven thickness, or if the FRP sheet is not fixed and pressure is applied until the bonding is completed, the uneven bonding will occur and the adhesion will be poor, so it is not practical. .

As a second method, when the top plate of the filled thermoplastic resin is melt-molded, uncured or semi-cured FR is used.
A prepreg sheet for P was arranged at a portion corresponding to the front end of the hole, and a hardening reaction was also performed by heat simultaneously with the molding of the top plate to integrate and reinforce the thermoplastic resin. Since the modulus of the prepreg sheet is large and the shrinkage of the prepreg sheet is small, a large residual stress is generated on the bonded surface of the prepreg sheet, and as a result, peeling, cracking and the like occur.

As a third method, after the top plate of the filled thermoplastic resin is melt-molded, the punched holes are formed, and the uncured or semi-cured FRP is formed by hand lay-up or the like on the edge of the opening of the top plate. After applying the layer, this FRP
The styrene in the unsaturated polyester of the layer affects the acrylic on the top plate, and the acrylic and polyester combine and cure as it is, and the FRP
A method was used in which the layers were strongly attached. Thereby, the thermal expansion and thermal shrinkage of the kiguchi surface are restrained to eliminate the concentration of thermal stress at the corner of the hole, and the kiguchi surface is given a strength not less than the residual stress due to the thermal shrinkage during cooling. As a result, cracks did not occur at the corners of the above-mentioned hole even after repeated use.

 However, this method also has the following disadvantages.

For example, a thermosetting prepreg for FRP impregnated with a reinforcing liquid obtained by cutting a glass mat into an appropriate width and length in a liquid resin for a matrix in which an unsaturated polyester resin liquid is mixed with an appropriate amount of a curing agent and an accelerator. Laminated along the edge of the hole by the hand lay-up method (about 4 to 5 mm thick)
Then, after the bubbles of the prepreg are defoamed by rolling, they are cured at room temperature for 4 hours, then put into a heating chamber, post-cured at 80 ° C. for 4 hours, and subjected to trimming-finishing. Although a method of integrating both is performed, this method employs a hand lay-up method, so that work efficiency is poor, and the finish tends to be uneven,
It takes a long time to cure, so that the productivity is poor, and because it is heated to a high temperature, the unsaturated polyester resin liquid is blended with styrene monomer and the like, so that styrene monomer is released, which is not preferable for environmental hygiene. There are drawbacks such as the possibility that the top plate of the filled thermoplastic resin may be distorted during curing, and improvement is required.

[Problems to be Solved by the Invention] In view of the above points, the present invention does not use a hand lay-up method, has a fast curing speed even at room temperature, and has no styrene monomer release or top plate distortion. The method of using a sheet is used to enhance the edge of the wood, has excellent heat resistance and mechanical strength, and has a defect such as a crack at the corner of the hole even when subjected to repeated heat history from a heating device such as a gas stove. It is an object of the present invention to provide an excellent synthetic resin top plate that does not occur.

[Means for Solving the Problems] The present inventors have conducted intensive studies in accordance with the above objects, and
The inventors have found that the problem can be solved by a method using a UV-curable prepreg sheet for FRP, and have reached the present invention.

A first invention of the present invention relates to a filler-containing synthetic resin top plate having a hole into which a heating device such as a gas stove is fitted. A synthetic resin top plate.

A second invention of the present invention is a method for manufacturing a synthetic resin top plate, which includes the following steps (a) to (c).

(A) A hole formed in a synthetic resin top plate containing a filler, into which a heating device such as a gas stove is fitted, and (b) an ultraviolet-curing type processed to have a width substantially equal to the width of the end of the opening of the hole. A prepreg sheet for FRP is attached to the entire edge of the kiguchi. (C) The prepreg sheet is cured by irradiating ultraviolet light to the prepreg sheet, and is firmly bonded and integrated over the entire edge of the kiguchi.

The filled synthetic resin top plate is manufactured by a known method by blending a known filler or the like with a resin such as a known thermoplastic resin or a thermosetting resin such as an acrylic thermoplastic resin. However, there is no particular limitation.

The ultraviolet-curable prepreg sheet for FRP used in the present invention is a prepreg sheet for FRP containing reinforcing fibers such as glass fibers which can be cured by irradiation with ultraviolet rays. A commercially available UV-curable prepreg sheet for FRP may be used. Since the prepreg sheet has already been processed into a sheet shape, it can be used for the purpose of the present invention, as it is after being cut or the like, or when there is release paper or the like, except for that.

Therefore, if the prepreg sheet is used, it is not necessary to use the conventionally used hand lay-up method,
The work efficiency can be improved and the finish can be improved.

The resin of the matrix of the prepreg sheet is, for example,
It is an unsaturated polyester containing a styrene monomer and a photoinitiator, and may be a mixture of the polyester and a reinforcing fiber such as a glass fiber.

The type, length, diameter, arrangement method, form (cloth, nonwoven fabric, etc.) of the reinforcing fibers such as glass fibers, the amount of the matrix mixed with the resin, and the presence or absence of surface treatment can be appropriately selected according to the purpose. .

The prepreg sheet is characterized in that it can be rapidly cured to a thick product (about several mm to about 30 mm in thickness) only by irradiating ultraviolet rays. The wavelength of the ultraviolet light is not particularly limited, but is preferably 330 to 440 nm, which is a region where ozone is not generated. If it is 365 to 410 nm, it shifts from the absorption region of the matrix resin, so that the energy of the irradiation light can be used effectively for curing, the curing speed is fast, and thick materials can be cured, while the skin and The irritation to the eyes is weak, which is more preferable.

For example, a 5 mm thick prepreg sheet at room temperature
The prepreg sheet having a thickness of 25 mm can be cured at room temperature in about 40 minutes. This is because, as compared with the case of using the thermosetting FRP prepreg having a thickness of about 4 to 5 mm as described above, the ultraviolet-curable FRP prepreg sheet used in the present invention can be cured very quickly, thus increasing the productivity. You can see that it can be done.

The ultraviolet light source is not particularly limited, and may be any of an ultraviolet fluorescent lamp, a high-pressure mercury lamp, a metal halide lamp, and sunlight.

Since the resin of the matrix of the prepreg sheet does not cure unless irradiated with ultraviolet light, there is an advantage that the pot life can be freely selected.

In addition, when irradiated with ultraviolet rays, the prepreg sheet hardens very quickly from the surface layer, and thus hardly emits styrene inside. Therefore, environmental problems associated with styrene release can be solved.

In the present invention, the method of attaching the prepreg sheet to the entire surface of the cut end of the hole of the filled thermoplastic synthetic resin top plate is not particularly limited. Although a manual operation may be used, a mechanical method or a method using a computer-controlled robot is preferable.

Before attaching the prepreg sheet, the entire surface of the tip end of the lip is laminated such as oil, dust, etc.
It is preferable to perform sanding or the like.

Next, as shown in FIG. 2 (B), the prepreg sheet 4 processed to have substantially the same width as the width of the cut end 3a of the punched hole 3 is attached to the entire cut end. After the attachment, it is preferable that the prepreg sheet 4 be cured by irradiating it with ultraviolet rays, and firmly adhered and integrated over the entire surface of the wood end 3a.

[Embodiment] FIGS. 3 to 6 show an embodiment of the synthetic resin top plate of the present invention having an ultraviolet-curing FRP layer firmly bonded and integrated on the entire surface of the end of the opening of the hole by the method of the present invention. Shown in the figure. However, the present invention is not limited to these embodiments without departing from the gist of the present invention.

The FRP layer 4A in FIG. 3 has a key shape and is formed flush with the upper surface of the top plate 1. FIG.
B is an L-shape, and in FIG. 5, the FRP layer 4C is formed in a U-shaped cross-section and bites into the flange 31 of the lip 3a,
6 is formed only along the peripheral surface of the opening 3a so as not to protrude above and below the top plate 1. FIG. In each case, the FPR layer is firmly laminated and adhered to the kiguchi 3a to be integrated.

A heating device such as a gas stove was fitted into the synthetic resin top plate of the present invention and used repeatedly.However, the FRP layer maintained a state of being firmly bonded and integrated without peeling off, and a hole in the hole. There were no cracks in the corners. On the other hand, in the case of the synthetic resin top plate without the FRP layer for reinforcement, cracks were formed in the corners of the punched holes during repeated use, making it unusable for practical use.

[Effects of the Invention] As described above, the present invention relates to a novel synthetic resin product top plate and a manufacturing method used for a kitchen counter and the like, and relates to a filled synthetic resin having a hole into which a heating device such as a gas stove is fitted. By strengthening the edge of the cut hole of the top plate made of UV-cured FRP layer, while having excellent heat resistance and mechanical strength,
Manufactures an excellent synthetic resin top plate that does not cause defects such as cracks in the corners of the holes even if it receives repeated heat history from a heating appliance such as a gas stove, with good productivity and without causing environmental problems. Now you can do it.

[Brief description of the drawings]

FIG. 1 is a schematic view of a kitchen counter, FIG. 2 (A) is a schematic view of a synthetic resin top plate 1 having a hole 3 formed in accordance with the shape of the heating device H, and FIG. FIG. 3 to FIG. 6 are schematic diagrams showing that an ultraviolet-curable FRP prepreg sheet 4 processed to be substantially the same width as the width of the cut end 3a of the punched hole 3 is attached to the entire cut end. 1 shows an embodiment of a synthetic resin top plate of the invention. 1: Top plate made of synthetic resin 2: Back guard integrally formed with the top plate 1 H: Heating device such as a hot plate 3: Drill hole 3a: Cut end 3a: Cut end 3: Cut end 3a Flange 4: UV curable FRP prepreg sheet 4A, 4B, 4C, 4D: UV curable FRP layer

──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. ⁶ identification code FI B29L 31:44 (58) Investigated field (Int.Cl. ⁶ , DB name) A47B 96/18 B29C 65/14 B29K 105: 16 B29K 105: 06 B29L 31:44 B29L 9:00

Claims (2)

(57) [Claims] 1. A top plate made of a synthetic resin containing a hole having a hole into which a heating device such as a gas stove is fitted. A top plate made of synthetic resin. 2. A method for producing a synthetic resin top plate, comprising the following steps (a) to (c). (A) A hole formed in a synthetic resin top plate containing a filler, into which a heating device such as a gas stove is fitted, and (b) an ultraviolet-curing type processed to have a width substantially equal to the width of the end of the opening of the hole. A prepreg sheet for FRP is attached to the entire edge of the kiguchi. (C) The prepreg sheet is cured by irradiating ultraviolet light to the prepreg sheet, and is firmly bonded and integrated over the entire edge of the kiguchi.