JP2000062097A - Granite-tone decorative plate - Google Patents

Abstract

PROBLEM TO BE SOLVED: To obtain the deep feel of material of high transparency and to enable molding work by laminating two transparent resin plates through a transparent adhesive layer containing colored resin chips. SOLUTION: In a decorative plate, various colored resin chips D1, D2 comprising artificial marble or/and a thermoplastic resin are dispersed on a transparent acrylic resin sheet B to manufacture an acrylic resin sheet E in which the colored resin chips D fixed by an adhesive layer C are dispersed. Next, a transparent acrylic resin plate F is laminated on the colored resin chip D dispersion surface side of the sheet E, and the laminate is hot-pressed in the arrow direction to be fused/integrated. The transparent resin sheet F is preferably a transparent thermoplastic resin sheet of an acrylic resin and others, and its thickness is made 0.3-3.0 mm for practical use. In this way, the deep feel of material of high transparency can be obtained.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a granite-like decorative board, particularly in the artificial marble market, which can freely express granite-like or marble-like designs, has high transparency, has a deep texture, and has a molding process. A possible transparent granite decorative board.

[0002]

2. Description of the Related Art The artificial marbles currently on the market are mainly made of acrylic resin-based and polyester resin-based products. These artificial marbles are commercialized by mixing inorganic fillers such as aluminum hydroxide with a resin as a main component, appropriately mixing crushed color chips of the artificial marble with the resin, and molding the mixture by thermosetting. For this reason, sheet-shaped (plate-shaped) products are difficult to thermoform, so they are mainly used for counters that use flat plates that do not require molding, and top plates for system kitchens, etc. In the field of products that require, the current situation is that they are commercialized by casting.

[0003]

On the other hand, due to the sophistication of the housing market in recent years, system kitchens, system baths, etc.
With the rapid spread of system housing equipment, consumers' needs for them are also diversified, and the needs for clean and high-quality design design are increasing along with higher quality and lower cost. In the system bus market, where growth is remarkable, there is a strong need for materials that are more luxurious, clean, and easier to maintain. For example, in bathtubs, products made of FRP and stainless steel were generally used, but in recent years, products made of artificial marble with a higher-grade feeling, and products made of acrylic resin that is clean and maintenance-free are rapidly becoming popular. . In addition, there is a great need for a mirror surface wall that is more luxurious and less likely to cause mold, etc., from tile walls and FRP walls, and there is a strong demand for granite mirror walls and granite bathroom counters.

However, in response to such changes in market needs, current product materials have the following problems and are not satisfactory. 1. Since the main component of the current artificial marble is a thermosetting resin, plate-shaped products cannot be molded.Therefore, the sink part of the system kitchen top plate is cut out and cast separately. Since the product is joined to the finished product, the loss of the product is large and the processing cost is also high. 2. Due to the manufacturing method, it is difficult to make thin plate products of artificial marble, and at present, thin products with a thickness of 3 mm or less have not been commercialized. For this reason, it is rarely used because of the cost problem in wall surface applications. 3. In addition, since artificial marble contains a large amount of inorganic filler, it has low transparency and it is difficult to express a clean and deep texture. 4. Deep drawing products such as bathtubs made of artificial marble are cast products and therefore have low productivity and high cost. 5. Most of the products are of single color, and it is difficult to express design such as granite or marble. 6. Bathtubs or wall materials made of polyester resin have problems in alkali resistance, weather resistance, stain resistance, and the like. 7. Acrylic resin bath tubs are cheap and highly transparent because they can be commercialized by vacuum forming from a plate-shaped resin plate, and a clean texture can be obtained, but it is difficult to express a granite tone and it is artificial by casting molding process. It lacks in luxury compared to a marble bathtub.

[0005]

SUMMARY OF THE INVENTION It is therefore an object of the present invention to provide a granite-like decorative board which is highly transparent, has a deep texture, and can be processed.

[0006]

DISCLOSURE OF THE INVENTION The present invention provides a granite-like decorative board in which two transparent resin plates B and F are laminated with a transparent adhesive layer C containing a color resin chip D interposed therebetween, and the granite-like makeup. The gist of the invention is a granite-like decorative plate in which a decorative sheet A is laminated on the lower surface of the plate.

Further, the gist of the present invention is a bathtub and a bathroom counter which are made of the above granite-like decorative board.

[0008]

BEST MODE FOR CARRYING OUT THE INVENTION Acrylic resin is particularly preferable as the material for the transparent resin plate and the decorative sheet that compose the granite decorative plate of the present invention. The reason for this is that a clean and highly transparent product can be obtained, and that it has excellent alkali resistance, stain resistance, durability, etc., which are important qualities required around bathrooms for bath applications, etc. It is possible to form a sheet-shaped or sheet-shaped product.

A feature of the present invention is that a transparent resin plate is laminated and integrated to form a decorative plate having a new function.

The granite decorative board of the present invention will be described below with reference to the drawings. The drawings show one embodiment of the granite-like decorative board of the present invention. FIG. 1 is an enlarged cross-sectional explanatory view of the granite-like decorative board, and FIG. 2 is an enlarged cross-sectional explanation of another aspect of the granite-like decorative board. It is a figure.

As shown in FIG. 1, the granite-like decorative board G of the present invention has various color resin chips D1 and D2 made of artificial marble or / and a thermoplastic resin dispersed on an acrylic resin sheet B to form an adhesive. A color resin chip D-dispersed acrylic sheet E fixed by a layer C is prepared, then a transparent acrylic resin plate F is laminated on the color resin chip D-dispersed surface side of this acrylic sheet E, and heat is applied in the direction of the arrow in FIG. It is formed by press working and fusion bonding.

FIG. 2 shows a granite-like decorative board H in which a decorative sheet A is laminated on the lower surface of the above-mentioned granite-like decorative board G. The decorative sheet A is an acrylic printed sheet a having a printing layer b formed by gravure-printing a granite-like pattern composed of a transparent portion and a concealed portion on the surface of a transparent acrylic resin sheet a'on a color acrylic laminate A '. It is laminated on. The granite-tone decorative plate of FIG. 2 is obtained by hot-pressing the decorative sheet A on the granite-tone decorative plate G of E and F shown in FIG.

In the decorative sheet A, the color acrylic resin A'may be one on which a pattern is directly printed or a color layer is laminated on the lower surface. When a colored layer is laminated on the lower surface, a transparent acrylic resin plate A'is used.

Further, the granite-like decorative plate H shown in FIG.
In the above, a printed sheet made of polyolefin resin may be attached to the lower surface of the surface on which the decorative sheet A is laminated. In this case, the decorative sheet A is not printed and the color acrylic plate A'is transparent. It is preferable to use an acrylic resin sheet, which is capable of deep drawing, for the granite-like decorative board shown in the above example.

Next, each element constituting the granite decorative board of the present invention will be described. When using artificial marble crushing chips as the color resin chips D to be used, those having a small diameter of 0.05 to 0.3 mm are used, and when using crushing chips having a thermoplastic resin as a main resin, It is preferable to use a relatively large particle diameter of 0.3 to 1.50 mm. As the thermoplastic resin, it is preferable to use a polyester resin type or an acrylic resin type.
In this case, the inorganic filler such as titanium oxide in the crushed chips is preferably 60% by weight or less. The color resin chip D is preferably used by mixing a small diameter one and a relatively large diameter one in an appropriate ratio. The mixing ratio of the small diameter color resin chip and the relatively large diameter color resin chip is 2
20% by weight or more and 80% by weight or less of the small-diameter color resin chips are preferable with respect to the total 100% by weight of the color resin chips of the seeds.

As the transparent resin sheet B for fixing the color resin chip D, it is preferable to use a transparent resin such as acrylic resin. The thickness of the transparent resin sheet B is not particularly limited, but in order to fix the color resin chip D,
Since the adhesive is continuously applied, it is preferable that the adhesive is as thin as about 0.1 to 0.5 mm because continuous coating with a roll coater, knife coater or the like can be performed. The acrylic resin sheet preferably used is an acrylic resin containing methyl methacrylate as a main component, in order to give flexibility to the sheet,
Polymethyl methacrylate modified with an acrylic ester or the like may be used or added.

The adhesive forming the adhesive layer C used for fixing the color resin chip D to the transparent resin sheet B has good adhesiveness to both the color resin chip D and the transparent resin sheet B. Of course, it needs to be transparent after curing. As such an adhesive, an acrylic resin type, a vinyl chloride / vinyl acetate type, an acrylic / urethane resin type, a urethane resin type, an epoxy resin type or the like can be used. The minimum thickness of the coating layer is that the color resin chips should not be peeled off and fall off by the next laminating step. Therefore, the coating amount is 10 to 30 g / m ² (thickness of about 1 to 5).
about μm).

In the transparent resin sheet B in which the color resin chips D obtained above are dispersed, the transparent resin sheet F is heated and pressed to sandwich and fix the color resin chips D completely. To stack. The transparent resin sheet F is preferably a thermoplastic transparent resin sheet such as acrylic resin. The thickness of the sheet F is not particularly limited, but a thickness of about 0.3 to 3.0 mm is practically preferable.

In the sheet E in which the color resin chips D obtained as described above are dispersed, the color resin chips D
In addition to laminating the transparent resin sheet F on the side, the decorative sheet A may be laminated on the transparent resin sheet B side. The decorative sheet A used has a thickness of 0.1 to 0.2 mm, for example.
The transparent acrylic resin sheet a'of No. 1 is gravure-printed with a granite or marble pattern to form a printed layer b, and the acrylic sheet has a concealing property, for example, a thickness of 0.2 mm.
It is possible to use one laminated on the above color acrylic resin plate A ', or one directly printed on the color acrylic resin plate A'without using the acrylic resin sheet a'. It is desirable to select a design that does not feel strange even if the design collapses during deep drawing such as in a bathtub.

The thickness of the granite-like decorative plate in which the decorative sheet A of the present invention is laminated is the same as that of the transparent resin sheet B which is laminated vertically.
Depending on the thicknesses of F and F, the composition and particle size of the color resin chip D to be used, and the thickness of the decorative sheet A, it is possible to make the product thickness in the range of minimum 0.6 mm to maximum 10 mm. .

Further, a printing sheet made of a polyolefin resin may be further attached to the lower surface of the surface of the granite decorative board H obtained above, on which the decorative sheet A is laminated. In this case, the printing sheet made of polyolefin resin is a sheet containing polypropylene, polyethylene or the like as a main component and having a printing layer formed on the surface thereof.
Therefore, in order to see this printed pattern, a transparent resin sheet is used as A'constituting the decorative sheet A.

Since a printing sheet made of polyolefin resin does not adhere to an acrylic resin plate or the like in a usual method, it is necessary to subject the surface of the polyolefin resin sheet to corona discharge treatment or to interpose an adhesive such as chlorinated olefin. Is. Alternatively, the main resin is an olefin resin, preferably a polyethylene resin, and has a thickness of 0.09 to 0.2 mm.
0.1% on the decorative surface of the decorative sheet (gravure printing sheet that has been anchored in advance to improve printability)
It is also possible to laminate a decorative sheet by heat-sealing and laminating an acrylic sheet having a thickness of up to 0.6 mm on the decorative sheet A via an adhesive.

As a method of giving a design to a deep-drawn molded product such as a bathtub or a bath counter, a transparent granite bathtub having a deep texture is obtained by gel-coating a back surface with a color resin after molding from a granite-like decorative board. Can also be created. As the color resin used here, it is preferable to use a gel coat resin based on an unsaturated polyester resin, which has a good adhesiveness with the acrylic resin constituting the granite decorative board.

[0024]

EXAMPLES Example 1 Manufacturing Example of Granite-Like Decorative Plate (1) Preparation of Color Resin Chip Dispersion Sheet E Thickness 0.20 mm × Width 850 mm × Length 1600 mm
An acrylic resin-based transparent adhesive is coated on the surface of the acrylic transparent resin plate B (the thickness, width, and length are omitted below) with a roll coater in a solid resin amount of 30 g / m ^2, and the acrylic resin is applied. A transparent adhesive layer C was formed. Next, the particle size of the main component of the polyester resin is 0.05 to
0.3 mm crushed color resin chip D1 and particle size 0.3
~ 1.50mm acrylic artificial marble crushed chips D
A color resin chip mixture obtained by mixing 2 by equal weight was shaken off from the hopper onto the surface of the adhesive layer C to prepare a color resin chip dispersion sheet E. The crushed color resin chips used were those containing three colors of blue, brown and white in equal weights. As the crushed chips of artificial marble, those having equal weights of two colors, black and dark blue, were used (Fig. 1).

(2) Preparation of Granite-Like Decorative Plate G On the upper layer of the color resin chip dispersion sheet E, a 2.70 mm × 850 mm × 1600 mm acrylic transparent resin plate F for deep drawing, which has been prepared in advance, is laminated and hot pressed. Acrylic granite-like decorative plate G of 2.90 mm in thickness and having a granite appearance was prepared by fusion-bonding by processing (FIG. 1). In hot pressing, a multi-step hot pressing machine was used, and a stainless steel plate subjected to a mirror surface plating treatment was used as a cover plate for the acrylic transparent resin layer F. The press working condition is 150 ° C. × 25 minutes, and the press pressure is 20 to 2
It was controlled to 5 kg / cm ² . 5 under pressure
After cooling to 0 ° C., the mirror plate was removed.

Example 2 Manufacturing Example of Granite-Like Decorative Plate with Laminated Decorative Sheet A (3) Preparation of Decorative Acrylic Printed Sheet a 0.10 mm × 850 mm × 1600 mm transparent acrylic sheet a ′ was transparent. A natural granite-like pattern composed of a portion and a concealed portion was gravure-printed to form a printing layer b, thereby preparing an acrylic printing sheet a.

(4) Preparation of acrylic decorative sheet A 2.00 mm × 850 mm × 160 prepared in advance
Acrylic decorative sheet A was prepared by hot pressing the acrylic printing sheet a prepared in (3) above on the surface of 0 mm gray deep drawing acrylic resin plate A ′ under the same conditions as in Example 1. .

(5) Preparation of Laminated Granite Decorative Veneer H The acrylic decorative sheet A was laminated on the lower surface of the granite veneer of Example 1 by hot pressing under the same conditions as in Example 1 (FIG. 2).

[Example 3] Manufacturing Example of Bathtub Composed of Laminated Granite Tone Decorative Plate
Vacuum molding was performed at a molding temperature of 180 ° C. using a bath mold of 0 mm × length 1400 mm × depth 550 mm.

On the back side of the obtained molded product, glass fiber 3
An unsaturated polyester resin (4521 manufactured by Nippon Yupica Co., Ltd.) containing 0% was sprayed by hand layup,
It was cured at 60 ° C. for 60 minutes. In this way, the FRP
A bath using a laminated granite decorative board backed up in 1. was manufactured. The bathtub had a high-class appearance and had good chemical resistance to various detergents.

Example 4 Manufacturing Example of Bathroom Counter Made of Laminated Granite-Style Decorative Board (6) Preparation of Decorative Sheet A granite-like pattern was printed on the lower surface of a 0.20 mm × 850 mm × 1600 mm transparent acrylic resin plate. Polyethylene printing sheets of the same size were laminated via a chlorinated olefin adhesive.

(7) Preparation of Bathroom Counter The decorative sheet prepared in (6) above was hot-pressed and laminated on the lower surface of the granite-like decorative plate obtained in Example 1 under the same conditions as in Example 1. . After cutting the obtained laminated granite style decorative plate into a width of 350 mm and a length of 1600 mm,
Heated in a heating furnace at 160 ° C for 10 minutes, width 25 mm x length 1600 mm and width 325 mm x length 1600 m
The bathroom counter was created by bending so that the part m was perpendicular to the direction parallel to the length direction. The thermoformability was good.

[0033]

The granite resin plate according to the present invention has the following features and effects. 1. Since it is made of acrylic resin, it has high transparency, and in particular, it solves the problems of alkali resistance, stain resistance, weather resistance, etc., which were the shortcomings of the current polyester artificial marble products as internal members such as system baths. In terms of design, it is possible to express a transparent and deep texture. 2. Thickness of 3.00m, which was difficult with the current artificial marble
Since it became possible to commercialize a granite-like decorative board having a size of m or less, it became possible to economically provide a high-quality granite-like wall. 3. Compared with granite-style bathtubs, which was a problem for acrylic resin bathtubs made from acrylic plates by vacuum molding, and higher-grade acrylic resin bathtubs, such as granite and marble, which are not currently on the market. It has become possible to provide it at a relatively low cost. 4. Since the composite thermal laminate sheet of polyethylene gravure printing sheet and thin acrylic sheet can be molded, it can be used for aprons, counters,
It has become possible to provide products with a variety of designs, such as granite and marble tones for applications such as makeup shelves.

As described above, in the granite plate of the present invention, the transparent acrylic resin layer appears to be dotted with the color resin chips, so that the transparent and deep texture can be obtained, and the natural granite-like printing layer is obtained. Layered under the color resin chip layer has a texture similar to that of a natural specular granite plate. Furthermore, it is possible to create bathtubs by vacuum forming, and it has become possible to provide granite-tone bathtubs that were difficult to commercialize until now.

[Brief description of drawings]

FIG. 1 is an enlarged cross-sectional explanatory view of a granite-like decorative board of the present invention.

FIG. 2 is an enlarged cross-sectional explanatory view of another granite-like decorative plate of the present invention.

[Explanation of symbols]

a'transparent acrylic sheet b Print layer a Acrylic printing sheet A'color acrylic resin plate A makeup sheet C transparent adhesive layer D color resin chip E Color resin chip dispersed acrylic sheet B Acrylic transparent resin plate F Acrylic transparent resin plate G Granite style decorative board H Granite style decorative board with laminated decorative sheets

Continued front page    (72) Inventor Masayuki Inoue             3816 Noborito, Tama-ku, Kawasaki-shi, Kanagawa Mitsubishi             Rayon Co., Ltd. Tokyo Technology and Information Center             Within F term (reference) 2D032 AA00 AB03 GA00                 4F100 AK01A AK01C AK01D AK03E                       AK04E AK25A AK25B AK25C                       AK25E AK41B AK41H AR00B                       BA03 BA04 BA05 BA06 BA07                       BA10A BA10C BA10E BA13                       DE05B DE05H GB08 GB90                       HB00B HB00D HB00H HB11E                       HB19B HB31E JB01 JL01                       JL02 JL06 JL09 JL10B                       JL10H JL11B JN01A JN01B                       JN01C JN01D

Claims (6)

[Claims] 1. A granite-like decorative plate in which two transparent resin plates B and F are laminated with a transparent adhesive layer C containing a color resin chip D interposed therebetween. 2. A granite decorative board which is obtained by laminating a decorative sheet A on the lower surface of the granite decorative board according to claim 1. 3. The granite-like decorative board according to claim 2, wherein the decorative sheet A is made of a transparent resin, and a colored layer is laminated on the lower surface of the decorative sheet. 4. The granite-like decorative board according to claim 2, wherein the decorative sheet A is made of a transparent resin, and a printing sheet containing a polyolefin resin as a main component is laminated on the lower surface thereof. 5. A bathtub formed by molding the granite-like decorative plate according to any one of claims 1 to 4. 6. A bathroom counter formed by molding the granite decorative plate according to any one of claims 1 to 4.