JP2001240459A - Artificial stone and method for producing the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a novel artificial stone and method for producing the same which can form simple and fine sight derived from characteristic of the material on the surface, the tone is hardly to be monotonic, and has high strength. SOLUTION: In this artificial stone, sand and powdered glass are mixed and melted to be integrated into one body.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an artificial stone and a method for producing the same, and more particularly, to an artificial stone having excellent aesthetics and used for interior and exterior materials of buildings and a method for producing the same.

[0002]

2. Description of the Related Art Hitherto, various materials have been employed as interior and exterior materials for buildings. In particular, in addition to a case where a natural material is used as it is as a material with an emphasis on aesthetics, an artificial material such as artificial marble and various tiles are often used. Among them, artificial marble has been developed in which an acrylic resin is mainly mixed with inorganic powder, and is used for kitchen top plates, various counter tops, vanities, flooring materials, wall materials, partition boards, and the like.

[0003] Further, decorative tiles manufactured by applying a material to the surface of ceramics and then firing the ceramics are also widely used as interior and exterior materials for buildings because of their ease of coloring and low cost.

[0004]

However, since artificial marble is a mixture of inorganic powder and resin,
There is a problem in maintaining aesthetics during actual use, such as being susceptible to aging, and mechanically weak resin parts being damaged during long-term use.

Further, since the surface layer constituting the surface of the conventional decorative tile is formed only of glaze, the color tone is monotonous due to the uniform gloss of the surface, and there is still room for improvement in aesthetics. However, there is also a problem in durability due to the use of clay and the like.

In view of the above-mentioned problems of the prior art, the object of the present invention is to make it possible to form a simple aesthetic appearance on the surface layer due to the characteristics of the material, to make it difficult for the color tone to be monotonous, and to be excellent in strength. An object of the present invention is to provide a new artificial stone and a method for producing the same.

[0007]

The above object is achieved by the invention described in each claim. That is, the characteristic configuration of the artificial stone according to the present invention resides in that the mixture of the sand material and the glass powder is heat-fused and integrated.

According to this configuration, the sand material having a low gloss and the glossy glass material are mixed, and the glossy portion of the vitreous material is appropriately distributed while exhibiting the characteristics of the material of the sand material. Since a sand material often has a cleavage plane, a different color tone can be exhibited depending on a viewing angle, and a new and beautiful artificial stone which has not existed conventionally can be provided. In addition, it is firmly bonded and bonded by the glass powder between the sand materials, and is excellent in strength and can be a durable artificial stone.

In the present specification, the term "sand material" is used as a concept including not only natural sand but also artificial sand (crushed sand) obtained by crushing rocks and the like.

The above-mentioned sand material and glass powder are mixed in a ratio of 1: 8 to 1:
The mixing ratio is preferably 0.5.

According to this configuration, it is possible to provide an artificial stone which exhibits the characteristics of the material possessed by the sand material, has a suitable mixture of vitreous gloss portions, and is excellent in aesthetic appearance. When the mixing ratio of the sand material and the glass powder is more than 1: 8, it is not preferable because the taste of the sand material is hardly formed, and when the mixing ratio is less than 1: 0.5, the glass material is glass. The binding action of the sand particles by the powder is weakened, and the strength is undesirably reduced.

Preferably, the mixture of the sand material and the glass powder further contains 10 to 40% of alumina powder.

According to this configuration, the gloss can be suppressed, the whiteness can be increased, and a finishing material having higher strength can be manufactured, which is convenient. In this case, it is preferable that the particle size of the alumina powder is selected to be slightly smaller than that of the sand material. When the compounding ratio of the alumina powder to the mixture of the sand material and the glass powder is less than 10%, the properties of alumina cannot be exhibited, and when the compounding ratio exceeds 40%, the strength is rather lowered, which is preferable. Absent. In addition, in this specification, all% means weight%.

Further, a characteristic feature of the method for producing an artificial stone according to the present invention is that a sand material and a glass powder are mixed, and this mixture is heated and fused to integrate the sand material and the glass powder. is there.

According to this configuration, it is possible to provide a novel method of manufacturing an artificial stone in which a simple aesthetic appearance derived from the characteristics of the material can be formed on the surface layer and the color tone is unlikely to be monotonous.

The sand material and the glass powder are mixed in a ratio of 1: 8 to 1:
It is preferable to mix at a mixing ratio of 0.5 and heat to at least 1100 ° C. or higher.

According to this configuration, it is possible to produce an artificial stone exhibiting the characteristics of the material of the sand material, having a vitreous glossy portion mixed appropriately, and having excellent aesthetics and excellent strength.

The heat fusion between the sand material and the glass powder is performed by
After heating at 00 to 900 ° C. for a predetermined time to form the glass powder, it is preferable that the glass powder be adhered to the surface and heated to at least 1100 ° C. or higher.

According to this structure, the bond between the sand particles can be strengthened, and a material having a more excellent strength can be manufactured. In addition, a beautiful surface finish peculiar to vitreous material can be formed in an appearance that emphasizes it, thereby increasing the commercial value. convenient.

[0020]

DESCRIPTION OF THE PREFERRED EMBODIMENTS Embodiments of the present invention will be described in detail below. The artificial stone of the present embodiment is formed by mixing various sand materials and glass powder, arranging them uniformly in a mold, and firing them at a predetermined temperature. The sand material is not particularly limited, and preferably has a normal particle size of about 0.074 to 2.4 mm, but may have a larger diameter or a smaller diameter. Furthermore, sea sand, river sand, mountain sand, sand containing a large amount of quartz or feldspar, other various sand materials, colored sand, and artificial sand materials such as crushed sand can also be used. Also, sand having a relatively uniform particle size, sand having a different particle size, or the like may be used.

It is preferable to use a glass powder having a small diameter finer than a sand material.
In addition to ordinary silicate glass, soda-lime glass and the like, glass powders of various compositions can be used, and colored glass powders and the like may be used.

When firing the sand material and the glass powder, a mold is not necessarily required. However, if the sand material and the glass powder are arranged and fired in a mold having a predetermined shape, it can be finished to a predetermined shape. preferable. Regarding the mold, it is possible to use a cast iron having heat resistance in consideration of baking, other metal, ceramic, carbon, etc. formed in a predetermined shape, in which case it is easy to remove from the mold after baking Having such a shape is convenient because the working efficiency can be increased. For example, if a mold formed of a bottom plate and a side plate (enclosing frame) is used, and the bottom plate is first removed after firing, the mold release becomes easy. Needless to say, the release agent may be applied to the surface of the mold and then fired.

When arranging the sand material and the glass powder in the mold,
These are sufficiently dried in advance to remove contained water. If the drying is insufficient, strong bonding in terms of strength becomes difficult, and cracks are generated, and bubbles are generated during firing, so that irregularities are formed on the surface, which is not preferable.

After placing the sand material and the glass powder in the mold,
It is fired as follows. That is, by heating to at least 1100 ° C. or more in the atmosphere, the sand particles are firmly bonded and joined by the fused glass material,
It is possible to manufacture interior and exterior materials having sufficient strength. In this case, if heating is performed rapidly, cracks may occur.

Further, once heating is performed at 700 to 900 ° C. for several hours (unbaking step), and then heating is performed again at a high temperature of about 1100 ° C. for several hours (final firing step), the sand particles are more strongly bonded to each other. You. When the first-stage heating is completed, the mixture is cooled to room temperature, and then the glass powder is adhered to the surface, and the second-stage high-temperature heating is performed. It comes to have a different aesthetic appearance and can have high commercial value. Furthermore, heating may be performed in multiple stages, and the heating method is not particularly limited. The atmosphere may be in a non-oxidizing state in which oxygen is blocked, and by introducing a specific gas into the heating atmosphere, it is possible to change the reactivity of the vitreous material to make various appearances appear on the material surface. .

[0026]

EXAMPLES As sand material, sea sand having a particle size distribution shown in Table 1 was used. As the glass powder, silicate glass powder (manufactured by Union Corporation, trade name: UP-09L) having a particle size of 0.15 μm or less occupying 96% was used. After heating these sea sand and glass powder in a drying furnace and drying them sufficiently, about 1: 1
, And placed in a heat-resistant metal mold so as to have a substantially constant height. This mold has a flat central recess of about 200 × 200 × 10 mm, and can withstand a high temperature of about 1300 ° C.

After the mixed sea sand and glass powder are inserted into the mold, they are placed in a heating furnace and gradually heated for 5 minutes.
It was heated and maintained at 60 ° C. for about 3.5 hours, and further heated and maintained at 800 ° C. for about 1.5 hours to prepare a molded body corresponding to the mold. Thereafter, it is heated to 1270 ° C. for about 10 hours,
After maintaining at this temperature for about 0.5 hour, it was gradually cooled in a furnace.

As a result, it was possible to produce an artificial stone material in which glossy vitreous material was appropriately arranged in the gaps between the white sand particles, had a pearl-like color tone as a whole, and was strong in strength. . Naturally, no cracks or other defects were visible in this artificial stone.

[0029]

[Table 1] [Other Embodiments] (1) In the above embodiment, an example was shown in which only a sand material and glass powder were mixed. You may make it improve the property, heat insulation, fire resistance, etc.

(2) Ceramic powder such as alumina powder may be further added to the sand material and glass powder in the above embodiment. For example, when the mixture is mixed at a ratio of sand material: glass powder: alumina powder = 1: 2: 1 and baked under the above-described conditions, gloss is suppressed, whiteness is increased, and an artificial stone material having higher strength is manufactured. We were able to. In this case, the particle size of the alumina powder is preferably selected to be slightly finer than that of the sand material, and the compounding ratio is preferably about 10 to 40% with respect to the mixture of the sand material and the glass powder.

(3) The artificial stone of the present invention is constructed and arranged on the surface of an interior material such as a ceiling material, an inner wall material and a floor material, or is constructed on the surface of an exterior material such as an outer wall material or a roof material. It can be widely used for things to be arranged, and also for walls, surfaces, legs, top plates and the like of furniture, furniture, etc., and may be used in combination with other materials or used alone.

Claims (6)

[Claims] An artificial stone in which a mixture of a sand material and a glass powder is heat-fused and integrated. 2. The method according to claim 1, wherein the sand material and the glass powder are 1: 8 to
2. The artificial stone according to claim 1, wherein the mixing ratio is 1: 0.5. 3. The artificial stone according to claim 1, further comprising 10 to 40% of an alumina powder based on the mixture of the sand material and the glass powder. 4. A method of manufacturing an artificial stone in which a sand material and a glass powder are mixed, and the mixture is heated and fused to integrate the sand material and the glass powder. 5. The method according to claim 1, wherein the sand material and the glass powder are mixed in a ratio of 1: 8 to 1:
The method for producing an artificial stone according to claim 4, wherein the mixture is mixed at a mixing ratio of 0.5 and heated to at least 1100 ° C. 6. The heat fusion between the sand material and the glass powder,
The method for producing an artificial stone according to claim 4, wherein after heating and molding at 700 to 900 ° C. for a predetermined time, glass powder is adhered to the surface and heated to at least 1100 ° C. or higher.