JP2002036259A - Method for manufacturing artificial marble - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for manufacturing artificial marble with a pattern, reducing the number of times for lap coating in forming a patterned resin layer for imparting appearance, which has a multicolor feeling, a multi-particle feeling, a depth felling or the like, to artificial marble by spraying to form the patterned resin layer for a short time and capable of enhancing the appearance having the multicolor feeling, the multi-particle feeling, the depth feeling or the like of artificial marble by forming a complicated pattern to the patterned resin layer. SOLUTION: The patterned resin layer 1 expressing a marble pattern is formed by spraying a paint 14 to the inner surface of a casting mold 3 by together using an air spray system and an airless spray system. Subsequently, an injection resin composition 8 is injected in the casting mold 3 to be molded and cured.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing artificial marble which can be used as a member of furniture or a building material.

[0002]

2. Description of the Related Art Conventionally, a patterned resin layer is previously formed on the inner surface of a casting mold for forming artificial marble on a surface corresponding to the surface of artificial marble as a product. A method of manufacturing a patterned artificial marble by injecting a casting resin composition into a casting mold and molding and curing the casting resin composition has been performed. The artificial marble molded product thus obtained is widely commercialized and used to form a wash counter, a kitchen counter, a bathtub, a wash bowl and the like.

In order to obtain a sense of quality, such artificial marble is required to have a multicolored appearance, a multi-grained feeling, a deep feeling, and the like. It is necessary to form one having a feeling of multiple grains, a feeling of depth, and the like. In order to form a patterned resin layer having such an appearance,
It is necessary to form the patterned resin layer by combining a thick part and a thin part.

In forming such a patterned resin layer, a paint is applied to the inner surface of a mold a plurality of times using an air-type spray gun, and the patterned resin layer is formed by the paint. And a method of partially changing its thickness.

[0005]

However, in such an air-type spray injection, it is necessary to spray the paint in an air stream, so that it is necessary to use a low-viscosity paint, which can be applied all at once. The coating amount was small and the number of times of coating was large. Therefore, the number of times of coating for forming the patterned resin layer is increased, and it takes time to form the patterned resin layer, and the thickness of the patterned resin layer is limited. . Therefore, when attempting to produce artificial marble having an appearance having a multicolored feeling, a multi-grained feeling, a deep feeling, and the like, it has been difficult to sufficiently improve such an appearance.

The present invention has been made in view of the above points, and forms a patterned resin layer by spraying to give an artificial marble a multicolored, multi-grained, and deepened appearance. In addition to reducing the number of times of coating to form a patterned resin layer in a short time and forming a complicated pattern on the patterned resin layer, artificial multi-colored, multi-grained, deep It is an object of the present invention to provide a method for producing artificial marble with a pattern that can improve the appearance.

[0007]

According to a first aspect of the present invention, there is provided a method for producing artificial marble, wherein an inner surface of a casting mold 3 is formed by using both an air type spray jet and an airless type spray jet. After forming a patterned resin layer 1 expressing a marble pattern by spraying a paint 14, a casting resin composition 8 is injected into a casting mold 3 and molded and cured. It is.

The invention of claim 2 is characterized in that the patterned resin layer 1 is formed by using a spray gun 2 provided with an air type spray injection device 2a and an airless type spray injection device 2b. Things.

A third aspect of the present invention is to use the spray gun 2 formed so that the relative angle between the air type spray injection device 2a and the airless type spray injection device 2b is variable. It is.

[0010]

Embodiments of the present invention will be described below.

The coating material 14 used for forming the patterned resin layer 1 is not particularly limited as long as it can form the patterned resin layer 1 having a deeper feeling, but it is of a translucent type. It is preferable to use

Such a translucent paint 14 includes a transparent resin component, a filler, a color toning agent for patterning,
Those prepared by blending a curing agent, a diluent and the like can be used.

[0013] As the transparent resin component, a methyl methacrylate monomer, a polyfunctional acrylic monomer, a prepolymer thereof, or a polymer called an acrylic syrup resin containing two or more of these polymers is used. Can be.

Further, as the filler, one having a refractive index of light close to that of the transparent resin component so as to maintain the appearance of transparency and depth when mixed with the transparent resin component. Preferably, it is used. For example, when the above acrylic syrup resin is used as a transparent resin component, it is preferable to use silica or glass powder.
Here, since silica and glass powder have almost the same refractive index, they can be used in combination. In this case, those mixed at an appropriate ratio can be used. The blending amount of the filler is not particularly limited, and an appropriate amount can be blended.

When silica or glass powder is used as a filler, it is preferable to use a filler having a particle size in the range of 3 to 40 μm in order to exhibit good transparency and depth. It is not limited to the range.

As the color tone agent, an appropriate pigment can be used. For example, various types such as titanium white, ceramic black, cadmium red, ceramic yellow, phthalocyanine green, and phthalocyanine blue can be used. .

As the curing agent, any one can be used as long as it can cure the transparent resin component.

The viscosity of the paint 14 can be adjusted by blending methyl methacrylate or the like as a diluent.

Here, the paint 14 used for the spraying by the air system is prepared to have a viscosity such that it can be sprayed in a state of being mixed in an air stream, and the viscosity is not particularly limited, but is preferable. Is 10-20P
(Poise). Further, since the paint 14 used for the airless spray injection is not mixed into the air current, a paint having a higher viscosity than that of the air paint is used. The viscosity is not particularly limited, but is preferably 20. -50P (poise).

On the other hand, the resin composition for casting 8 is not particularly limited, but preferably has the same composition as the paint 14. That is, as described above, paint 1
In the case where a material composed of an acrylic syrup resin is used as 4, it is preferable to use a material composed of an acrylic syrup resin and a filler such as glass powder or silica, and in this case, a more excellent transparency and depth can be exhibited. Is what you can do.

Next, the manufacturing process of the artificial marble 4 will be described with reference to FIG.

As the casting mold 3, a pair of molds 3a,
3b, and a concave portion 12 for forming a cavity 13 is formed on a surface of each mold to be clamped. A heating pipe 7 is formed inside each of the molds 3a and 3b, and a heat medium such as steam passes through the pipe 7 during heat molding. Also, one of the molds 3b has the inside of the recess 12 and the mold 3b.
An injection nozzle hole 5 communicating with the outer surface of the mold body 3 is formed, and a discharge nozzle hole 6 communicating with the inside of the concave portion 12 and the outer surface of the mold body 3a is formed in the other mold body 3a. The injection nozzle hole 5 and the discharge nozzle hole 6 may be formed on the same mold 3a (3b).

In manufacturing the artificial marble 4, first, one of the molds 3a and 3b is heated to 40 to 60 ° C. while the mold is not clamped, and one mold 3b is heated to 40 to 60 ° C.
The paint 14 is sprayed toward the bottom surface of the concave portion 12 of the mold body 3b using the spray gun 2 or the like to form the patterned resin layer 1 having a pattern (marble pattern) imitating natural marble. At this time, the patterned resin layer 1 is formed in a semi-cured state.

In spraying the paint 14, the air type spray injection and the airless type spray injection are simultaneously performed. Here, the spraying by the air method means that the paint 14 is introduced into an air stream,
The method of spraying the paint 14 from a nozzle or the like in a state where the paint 14 is mixed in an air stream. On the other hand, the airless spray spray is a method of spraying only the paint 14 from a nozzle or the like by pressurizing the paint 14 itself. Say.

When the paint 14 is jetted in this manner, a more complicated color tone can be produced by sequentially jetting a plurality of types of paints 14 having different color tones.

When the patterned resin layer 1 is formed in this manner, the coating of the paint 14 is performed not only by the air method in which the coating amount per hour of the paint 14 is small, but also by the airless method in which the amount of coating per hour is large. Therefore, the thickness of the patterned resin layer 1 can be increased, and the paint 1
4, the coating time can be reduced, and the patterned resin layer 1 can be formed efficiently. In addition, by simultaneously spraying the paint 14 in different manners as described above, the patterned resin layer 1 is formed.
A complicated change in thickness can be formed. Further, when the paint 14 sprayed by the air method and the paint 14 by the airless method have different color tones,
The patterned resin layer 1 having a complicated pattern can be easily formed.

Next, the molds 3a and 3b are clamped so that the concave portions 12 face each other, thereby forming the casting mold 3 and forming the cavity 13 in the casting mold 3.

In this state, one end of the injection pipe 10 for resin injection is connected to the injection nozzle hole 5. This injection pipe 10
Is connected to a pouring tank 9 that holds the casting resin composition 8 therein, and the tip thereof is disposed inside the casting resin composition 8. Then, the inside of the injection tank 9 is pressurized by injecting the pressurized air 11 into the inside of the injection tank 9, and the casting resin composition 8 in the injection tank 9 is injected by this pressure into the injection pipe 7 and the injection pipe 9. Cavity 1 of casting mold 3 with casting resin composition 8 through nozzle hole 5
Inject into 3. At this time, the air in the cavity 13 is discharged from the discharge nozzle hole 6 to the outside of the casting mold 3, and the casting resin composition 8 is smoothly injected. In addition, the casting resin composition 8 is poured into the casting mold 3 in this manner, and the mold temperature is heated to 50 to 110 ° C.
Hold for 0 minutes. At this time, the copolymerization reaction between the reactive unsaturated group and the polymerizable monomer present in the resin component of the casting resin composition 8 progressed, and the artificial marble 4 was cured and molded, and was in a semi-cured state. The patterned resin layer 1 is also completely cured, and the patterned resin layer 1 is formed with good adhesion to the artificial marble 4.

After molding, the mold 3 of the casting mold 3 is formed.
The artificial marble 4 can be obtained by separating the molds a and 3b and opening the mold.

In the artificial marble 4 thus formed, a complicated change in thickness and a complicated pattern are formed on the patterned resin layer 1 representing a marble pattern, so that a multicolored feeling is obtained. In addition, the graininess and depth are enhanced, and a luxurious appearance appears. The artificial marble 4 thus formed is hard to be damaged. Therefore, the artificial marble 4 can be used to construct various members such as a washbasin, a kitchen counter, a bathtub, and a washbasin in a field called a water area such as a toilet, a bathtub, and a kitchen area.

Next, the structure of the spray gun 2 used for spraying the paint 14 by the air method and the airless method will be described with reference to FIGS. In the following description, the upper side of FIG. 2 is referred to as upper side, the lower side as lower side, the left side as front, and the right side as rear.

The spray gun 2 has a configuration in which an air type spray injection device 2a and an airless type spray injection device 2b are provided on a base 15 in parallel.

The air type spray injection device 2a and the airless type spray injection device 2b are arranged in parallel on both sides of the upper part of the base 15, and
A connecting portion 20 extends laterally from the inner side of the insides a and 2b, and each of the jetting devices 2a and 2b is attached to the base 15 by a connecting fitting 21 attached to the connecting portion 20. I have.

Here, the connection fitting 21 is connected to each of the injection devices 2a,
2b is formed into a substantially L-shaped cross-section including an injector connecting piece 21a disposed along the lower surface of the connecting portion 20 and a base connecting piece 21b extending downward from an outer end of the injector connecting piece 21a. Have been. The injection device connecting piece 21a is
Are arranged along the upper surface of the injection device connecting piece 21a and the connecting portion 20 are connected to a vertical rotation shaft 22 (hereinafter referred to as a horizontal rotation shaft 22).
), The injection devices 2a and 2b are connected to the connection fitting 21 so as to be rotatable about the horizontal rotation shaft 22. The base connecting piece 21b is disposed along the upper side surface of the base 15, and the base connecting piece 21b and the base 1
Reference numeral 5 denotes a rotating shaft 23 (hereinafter, referred to as a rotating shaft 23) that is substantially orthogonal to the front-rear direction of each of the injectors 2a and 2b and substantially orthogonal to the vertical direction.
The connection fitting 21 is connected to the base 15 so as to be rotatable about the vertical rotation shaft 23 by a vertical rotation shaft 23).

For this reason, each of the injection devices 2a and 2b is formed so as to be rotatable with respect to the base 15 about a horizontal rotation shaft 22 and a vertical rotation shaft 23 which are substantially orthogonal to each other.

Further, a grip portion 24 extends downward from the base 15, and the user can use the spray gun 2 while holding the spray gun 2 by gripping the grip portion 24.

An injection nozzle 16 is formed at the front end of each of the air type spray injection device 2a and the airless type spray injection device 2b. In addition, each injection device 2
An operation knob 26 for adjusting the injection amount of the paint 14 from the injection nozzle 16 is provided at the rear end of the nozzles a and 2b. An operation knob 27 for adjusting the opening amount of the injection nozzle 16 is provided on the outer side of each of the injection devices 2a and 2b. The degree of spread of the paint 14 can be adjusted.

Further, at the rear of each injection device 2a, 2b,
The downstream ends of the air pipes 18a and 18b through which the pressurized air flows are respectively connected via the flow rate adjusting valve 31. Here, when pressurized air is supplied from the air pipes 18a, 18b to each of the spray devices 2a, 2b, the valve of the spray nozzle 16 is opened by the pneumatic control mechanism so that the paint 14 is sprayed from the spray nozzle 16. Has become. The flow control valve 31 has a flow control valve 31.
An operation lever 19 for adjusting the opening amount of is provided.
By adjusting the opening amount of the flow control valve 31, the flow rate of the pressurized air supplied to each of the injection devices 2a and 2b can be adjusted.

Here, the air type spray injection device 2
In a, the air flow of the pressurized air supplied from the air pipe 18a is supplied to the injection nozzle 16, and when the valve of the injection nozzle 16 is opened, the air flow of the pressurized air is It is to be injected from. A paint cup 17 for holding the paint 14 is provided in front of the air type spray injection device 2a, and the paint 14 in the paint cup 17 is pneumatically applied by a gravity type or a suction type. Are introduced into the pressurized air stream in the spray injection device 2a and mixed. For this reason, when the valve of the injection nozzle 16 is open, the paint 14 is injected from the injection nozzle 16 in a state where the paint 14 is mixed in the airflow of the pressurized air.

On the other hand, one end of a paint supply pipe 28 through which the pressurized paint 14 flows is connected to the front of the airless spray spray device 2b. The paint 14 supplied to the ejection device 2b is supplied toward the ejection nozzle 16. The other end of the paint connection pipe 28 is connected to a paint tank 30 in which the paint 14 is held. The paint 14 in the paint tank 30 is mixed with air into the airless type spray injection device 2b through the paint supply pipe 28 by a paint supply means driven by an appropriate method such as a pneumatic type, an electric type, and an engine type. In the illustrated example, a plunger type pump 29 is provided in the middle of the paint supply pipe 28 as paint supply means. Therefore, the injection nozzle 1
When the valve No. 6 is open, only the paint 14 is sprayed from the spray nozzle 16 without being mixed with air.

The downstream end of the air supply main pipe 18 through which the pressurized air flows is connected to the grip portion 24.
The upstream end of the air supply main pipe 18 is connected to pressurized air supply means such as an air pump or an air cylinder. The main air supply pipe 18 is connected to an open / close valve 32 provided on the grip portion 24. The main air supply pipe 18 is connected to the air supply pipes 18a and 18a via the open / close valve 32.
18b is connected to the upstream end. This on-off valve 32
The operation switch 2 for controlling the opening / closing operation of the on-off valve 32
5 is provided so as to protrude forward from the grip portion 25. When the operation switch 25 is pressed, the open / close valve 32 is opened, and the air supply main pipe 18 is connected to each of the air supply pipes 18a, 18a.
18b is supplied with pressurized air at the same time.
When the pressing state of No. 5 is released, the on-off valve 32 is closed so that pressurized air is not supplied to both the air supply pipes 18a and 18b.

In the air gun 2 thus configured, when the user presses the operation switch 25, the pressurized air is supplied from the main air supply pipe 18 to each of the air supply pipes 18a, 1a.
8b, is simultaneously supplied to each of the injection devices 2a, 2b,
In each of the ejection devices 2a and 2b, the valve of the ejection nozzle 16 is opened by pneumatic control, and the paint 14 is ejected. Therefore, the air type spray injection device 2
a) The spray nozzle 16 of the airless type sprays the paint 14 at the same time as injecting the paint 14 from the spray nozzle 16 by the air type.
The paint 14 can be sprayed from the spray nozzle 18 by an airless method. When the pressing state of the operation switch 25 is released, the supply of the pressurized air from the main air supply pipe 18 to each of the air supply pipes 18a and 18b is interrupted, and the pressurized air is not supplied to each of the injection devices 2a and 2b. ,
In each of the injection devices 2a and 2b, the valve of the injection nozzle 16 is closed, and the injection of the paint 14 in each of the injection devices 2a and 2b can be stopped at the same time.

The paint 1 was sprayed using the spray gun 2.
In order to perform the spraying of No. 4, each of the spraying devices 2 a and 2 b of the air type spraying device 2 a and the airless type spraying device 2 b is connected to the base 15 by the horizontal rotation shaft 2.
2 and the vertical rotation shaft 23,
The spray direction of the paint 14 can be adjusted by changing the arrangement state of the a and 2b with respect to the substrate 15, and the spray direction is changed with the spray gun 2 fixed, so that the paint 14 can be uniformly distributed over a wide range. Can be applied. Here, FIG. 5 shows the respective spraying devices 2a, 2a of the air type spraying device 2a and the airless type spraying device 2b.
b shows a state where the paint 14 is applied over a wide range of the bottom surface of the concave portion 12 of the mold body 3b by rotating the b around the vertical rotation shaft 23 with respect to the base 15.

As shown in FIG. 6, each injection device 2a,
If the front ends of the air type spray injection device 2a and the airless type spray injection device 2b are arranged close to each other and the rear ends are separated by rotating the 2b around the horizontal rotation shaft 22, each injection The spray directions of the paints 14 sprayed from the devices 2a and 2b can be made to cross. When the position where the spraying directions intersect is arranged on the bottom surface which is the coating surface of the paint 14 on the inner surface of the concave portion 12 of the mold 3a, and the paint 14 is sprayed on the coating surface, two types are obtained. The paint 14 collides with the paint 14 to form a complicated pattern and irregularities on the patterned resin layer 1 formed by the paint 14 in a state of being mixed in a complicated manner. Good multicolor feeling, multi-grain feeling, and deep feeling can be exhibited.

Further, each of the injection devices 2a and 2b is
2, the angle between the spraying directions of the paint 14 sprayed from the spraying devices 2a and 2b can be adjusted by changing the relative angle between the spraying devices 2a and 2b. At this time, the position where the jetting directions of the two kinds of paints 14 intersect can be changed to an arbitrary position shown by A, B, C, and D in FIG. Then, the paint 14 is sprayed onto the application surface at the intersection of the spray direction of the paint 14. By doing so, the collision state between the two paints 14 is changed by changing the position where the jetting directions of the two paints 14 intersect, thereby forming the patterned resin layer 1 formed by the paint 14. The artificial marble 4 having a different appearance can be obtained by changing the shape of the pattern and the degree of the unevenness. Therefore, by changing the ejection position of the paint 14 in the ejection direction, artificial marbles 4 having various appearances can be obtained.

[0046]

The present invention will be described below in detail with reference to examples.

Example 1 An acrylic syrup resin (manufactured by Nippon Fellows Co., Ltd .; product number "AC-102") was used as the paint 14 for spraying in the air system with methyl methacrylate at an acrylic syrup resin concentration of 20% by mass. For 100 parts by mass diluted so that
Silica (average particle size 7 μm; manufactured by Tatsumori Corporation;
20 parts by mass of YSTLITE E-2), and 0.1 to 1.0 parts by mass of a color tone agent and 3.5 parts by mass of a curing agent (manufactured by Kayaku Akzo Co., Ltd .; product number "Parcadox 16"). What was done was used. Here, the paint 14 was prepared as a color tone agent by using three kinds of compounds containing a brown pigment (iron oxide buff brown), a black pigment (iron oxide) or a white pigment (titanium white).

The paint 14 used for the airless spray injection was prepared by diluting the above-mentioned acrylic syrup resin with methyl methacrylate so that the concentration of the acrylic syrup resin was 65% by mass, based on 100 parts by mass. The above silica was added in an amount of 20 parts by mass, and a mixture of 0.2 to 1.0 parts by mass of a color tone agent and 3.5 parts by mass of the above curing agent was used. Here, three kinds of paints 14 were prepared as a toning agent in which a black pigment (ceramic black), a white pigment (titanium white) or a yellow pigment (ceramic yellow) was blended.

The resin composition for casting 8 was prepared by adding 150 parts by mass of the above silica to 100 parts by mass of the acrylic syrup resin, and further adding 0.2 parts by mass of a blue pigment (phthalocyanine blue). And 4.0 parts by mass of the above curing agent.

Using the coating material 14 and the casting resin composition 8 prepared as described above, artificial marble 4 was produced as follows.

First, as shown in FIG. 1, while the temperature of one mold 3a of the casting mold 3 is maintained at 60 ° C., the paint 14 is sprayed onto the bottom of the concave portion 12 of the mold 3a. , 10
A patterned resin layer 1 having a thickness change in the range of 0 to 1000 μm was formed.

Here, the paint 14 was sprayed using the spray gun 2 as shown in FIGS. 2 to 4. At this time, the air type spray jet and the airless type spray jet were simultaneously performed. In this spraying, the air-based paint 14 is replaced with a brown-based paint, a black-based paint, and a white-based paint sequentially, and is ejected.
As No. 4, black, white, and yellow types were sequentially exchanged and jetted.

Next, the pair of molds 3a and 3b are overlapped and clamped, and the casting resin composition 8 is injected into the cavity 13 through the injection nozzle hole 5, and is cured by heating at 90 ° C. for 120 minutes. Was.

As a result, an artificial marble 4 having transparency, a complex pattern formed on the patterned resin layer 1, and improved multicolor, multi-grain, and deep feeling was obtained.

Example 2 An acrylic syrup resin (manufactured by Nippon Fellow Co., Ltd., product number "AC-102") was used as the paint 14 for spraying in the air system with methyl methacrylate at a concentration of 20% by mass of the acrylic syrup resin. For 100 parts by mass diluted so that
22 parts by mass of glass powder (average particle size: 5 μm; manufactured by Nippon Frit Co., Ltd .; product number “CF0007-05B”) is added, and further, 0.15 to 0.8 parts by mass of a color toning agent and a curing agent (manufactured by Kayaku Akzo Co., Ltd.) ; Part number "Parcadox 16")
What mixed 3.0 mass parts was used. Here paint 14
Prepared three kinds of colorants containing a brown pigment (iron oxide buff brown), a black pigment (iron oxide) or a yellow pigment (ceramic yellow).

As the paint 14 used for the airless spray injection, 100 parts by mass of the above acrylic syrup resin diluted with methyl methacrylate so that the concentration of the acrylic syrup resin becomes 55% by mass. , 30 parts by weight of the above glass powder,
Further, 0.15 to 1.0 part by mass of a color tone agent and the above curing agent3.
What mixed 5 mass parts was used. Here, the paint 14 is
As the color toning agent, three kinds of pigments containing a black pigment (ceramic black), a white pigment (titanium white) or a brown pigment (iron oxide buff brown) were prepared.

The same resin composition as in Example 1 was used as the resin composition 8 for casting.

Using the coating material 14 and the casting resin composition 8 prepared as described above, artificial marble 4 was produced as follows.

First, as shown in FIG. 1, while the temperature of one mold 3a of the casting mold 3 is maintained at 65 ° C., the paint 14 is sprayed onto the bottom of the concave portion 12 of the mold 3a. , 10
The patterned resin layer 1 having a thickness change in the range of 0 to 1500 μm was formed.

Here, the paint 14 was sprayed by using a spray gun 2 as shown in FIGS. 2 to 4. At this time, the air spray and the airless spray were simultaneously performed. In this spraying, the air-based paint 14 is replaced with a brown-based paint, a black-based paint, and a yellow-based paint, and is then sprayed.
As No. 4, black type, white type and brown type were sequentially changed and jetted.

Next, the pair of molds 3a and 3b are overlapped and clamped, and the casting resin composition 8 is injected into the cavity 13 through the injection nozzle hole 5, and is cured by heating at 90 ° C. for 120 minutes. Was.

As a result, an artificial marble 4 having transparency, a complex pattern formed on the patterned resin layer 1, and improved multicolor feeling, multi-grain feeling and depth feeling was obtained.

(Example 3) As a paint 14 used for the air type spray injection, 60 parts by mass of an acrylic syrup resin (manufactured by Nippon Fellow Co., Ltd .; product number "AC-102") and an acrylic syrup resin (manufactured by Mitsui Chemicals, Inc .; (Part number "XE924-1") A mixed resin with 40 parts by mass was diluted with methyl methacrylate so that the concentration of the mixed resin was 15% by mass, and 100 parts by mass of glass powder (average particle diameter 5 μm; Japan) 15 parts by mass of Frit Co., Ltd .; product number "CF0007-05B"), 0.08 to 1.50 parts by mass of a color-toning agent and a curing agent (Kakuyaku Akzo Co., Ltd .; product number "Parcadox 16") 3 A mixture containing 0.0 parts by mass was used. Here, the paint 14 is a mixture of three types of color toning agents containing a brown pigment (natural inorganics sinus iron oxide amber), a white pigment (zinc oxide) or a yellow pigment (titanium pigment yellow buff). Prepared.

As the paint 14 used for the airless spray injection, a mixture of the above two kinds of acrylic syrup resin diluted with methyl methacrylate so that the concentration of the mixed resin becomes 70% by mass is used. 30 parts by mass of the above-mentioned glass powder was added to the parts by mass, and a mixture of 0.2 to 1.3 parts by mass of the color tone agent and 3.8 parts by mass of the above curing agent was used. Here paint 14
Is a black pigment (carbon black) as a toning agent,
Three kinds of pigments containing a red pigment (quinaclodon maroon medium red) or a brown pigment (iron oxide buff brown) were prepared.

The same resin composition as in Example 1 was used as the resin composition 8 for casting.

Using the paint 14 and the casting resin composition 8 prepared as described above, artificial marble 4 was produced as follows.

First, as shown in FIG. 1, while the temperature of one mold 3a of the casting mold 3 is maintained at 70 ° C., the paint 14 is sprayed onto the bottom surface of the concave portion 12 of the mold 3a. , 30
The patterned resin layer 1 having a thickness change in the range of 0 to 1500 μm was formed.

Here, the paint 14 was sprayed by using a spray gun 2 as shown in FIGS. 2 to 4. At this time, the air spray spray and the airless spray spray were simultaneously performed. In this spraying, the air-based paint 14 is replaced with a brown-based paint, a white-based paint, and a yellow-based paint, which are sequentially replaced.
As No. 4, black, red, and brown ones were sequentially replaced and jetted.

Next, the pair of molds 3a and 3b are overlapped and clamped, and the casting resin composition 8 is injected into the cavity 13 through the injection nozzle hole 5, and is cured by heating at 90 ° C. for 130 minutes. Was.

As a result, an artificial marble 4 having transparency, a complex pattern formed on the patterned resin layer 1, and improved multicolor, multi-grain, and deep feeling was obtained.

Example 4 An acrylic syrup resin (manufactured by Nippon Fellows Co., Ltd .; product number "AC-102") was used as the paint 14 for spraying in the air system with methyl methacrylate at a concentration of 18% by mass of the acrylic syrup resin. For 100 parts by mass diluted so that
Silica (average particle size 5 μm; manufactured by Tatsumori Corporation;
YSTLITE ZA-30 ”) and glass powder (average particle size 8 μm; manufactured by Nippon Frit Co., Ltd .; product number“ ST-
246 ") at a mass ratio of 50/50 to 17% by mass.
0.15 to 0.9 parts by mass of a color tone agent and a curing agent (manufactured by Kayaku Akzo Co., Ltd .;
6 ") 3.0 parts by mass was used. Here, the paint 14 is a brown pigment (iron oxide buff brown), a white pigment (zinc sulfide) or a yellow pigment (nickel azo green yellow) as a color tone agent.
Were prepared.

The paint 14 used for the airless spraying was prepared by diluting the above-mentioned acrylic syrup resin with methyl methacrylate so that the concentration of the acrylic syrup resin became 65% by mass. The mixture of the above silica and glass powder was
5 parts by mass were added, and a mixture of 0.3 to 1.5 parts by mass of a color tone agent and 3.2 parts by mass of the above curing agent was used. Here, the paint 14 is a mixture of three kinds of colorants containing a black pigment (bone black), a red pigment (BON Maroon light red) or a brown pigment (natural inorganics, sinus iron oxide amber). Prepared.

The same resin composition as in Example 1 was used as the casting resin composition 8.

Using the coating material 14 and the resin composition 8 for casting prepared as described above, artificial marble 4 was produced as follows.

First, as shown in FIG. 1, while keeping the temperature of one mold 3a of the casting mold 3 at 50 ° C., the paint 14 is sprayed onto the bottom surface of the concave portion 12 of this mold 3a. , 50
A patterned resin layer 1 having a thickness change in the range of 0 to 1800 μm was formed.

Here, the paint 14 was sprayed by using a spray gun 2 as shown in FIGS. 2 to 4. At this time, the air spray and the airless spray were simultaneously performed. In this spraying, the air-based paint 14 is replaced with a brown-based paint, a black-based paint, and a white-based paint sequentially, and is ejected.
As No. 4, black, white, and yellow types were sequentially exchanged and jetted.

Next, the pair of molds 3a and 3b are overlapped and clamped, and the casting resin composition 8 is injected into the cavity 13 through the injection nozzle hole 5, and is cured by heating at 90 ° C. for 110 minutes. Was.

As a result, an artificial marble 4 having transparency, a complex pattern formed on the patterned resin layer 1, and improved multicolor feeling, multi-grain feeling and depth feeling was obtained.

(Example 5) As the paint 14 used for the air type spray injection, 75 parts by mass of an acrylic syrup resin (manufactured by Nippon Fellow Co., Ltd .; product number "AC-102") and an acrylic syrup resin (manufactured by Mitsui Chemicals, Inc .; Silica (average particle size: 5 μm; Tatsumori) with 100 parts by mass of a resin mixture with 25 parts by mass of a mixed resin having a product number of “XE924-1” diluted with methyl methacrylate so as to have a concentration of 20% by mass. Co., Ltd .; product number "CRYSTLI"
TEZA-30 ") and glass powder (average particle size 8μ)
m; manufactured by Nippon Frit Co., Ltd .; product number "ST-246")
15% by mass of a mixture having a mass ratio of 60/40 with 0.1 to 0.8 parts by mass of a color tone agent and 3.1 mass% of a curing agent (manufactured by Kayaku Akzo Co., Ltd .; product number "Parcadox 16") What mixed parts was used. Here, three types of paints 14 were prepared as a color tone agent, in which a brown pigment (iron oxide buff brown), a white pigment (titanium white), or a yellow pigment (chrome yellow) was blended.

The paint 14 used for the airless spray injection was prepared by diluting the above mixed resin with methyl methacrylate so that the concentration of the mixed resin was 65% by mass. 23 parts by mass of a mixture of the above silica and glass powder were added, and 0.1 to 0.7 parts by mass of a color tone agent and 3.2 parts by mass of the above curing agent were further blended. Here, as the paint 14, three kinds of color tone agents were prepared in which a black pigment (ceramic black), a red pigment (cadmium mercury red) or a brown pigment (iron oxide buff brown) was blended.

The same resin composition as in Example 1 was used as the resin composition 8 for casting.

Using the coating material 14 and the casting resin composition 8 prepared as described above, artificial marble 4 was produced as follows.

First, as shown in FIG. 1, while the temperature of one mold 3a of the casting mold 3 is maintained at 50 ° C., the paint 14 is sprayed onto the bottom of the concave portion 12 of the mold 3a. , 15
A patterned resin layer 1 having a thickness change in the range of 0 to 1800 μm was formed.

Here, the paint 14 was sprayed by using a spray gun 2 as shown in FIGS. 2 to 4. At this time, the air spray and the airless spray were simultaneously performed. In this spraying, the air-based paint 14 is replaced with a brown-based paint, a black-based paint, and a white-based paint sequentially, and is ejected.
As No. 4, black, white, and yellow types were sequentially exchanged and jetted.

Next, the pair of molds 3a and 3b are overlapped and clamped, and the casting resin composition 8 is injected into the cavity 13 from the injection nozzle hole 5, and is cured by heating at 90 ° C. for 110 minutes. Was.

As a result, an artificial marble 4 having transparency, a complex pattern formed on the patterned resin layer 1, and improved multicolor, multi-grain, and deep feeling was obtained.

[0087]

According to the method for producing artificial marble according to the first aspect of the present invention, the paint is sprayed on the inner surface of the casting mold by using both the air spray spray and the airless spray spray. After forming a patterned resin layer that expresses the marble pattern by, injecting the casting resin composition into the casting mold and molding and curing, as well as the air method with a small application amount per time, The paint is applied even by the airless method, which has a large amount of coating per time, and the thickness of the patterned resin layer can be increased, and the coating time of the paint can be shortened to efficiently form the patterned resin layer. It is possible to form a complicated change in the thickness of the patterned resin layer by simultaneously performing the spraying of the paint by the different methods as described above,
Furthermore, if different paints are used as the paint sprayed by the air method and the paint sprayed by the airless method, a patterned resin layer having a complicated pattern can be easily formed. As a result, complex patterns of thickness and complex patterns are formed on the patterned resin layer that expresses the marble pattern, resulting in a multicolored, multi-grained, deep feeling, and a luxurious appearance. Thus, an artificial marble having the following formula can be obtained.

The second aspect of the present invention is to form a patterned resin layer by using a spray gun provided with an air type spray injection device and an airless type spray injection device. It is possible to form a patterned resin layer by simultaneously and easily performing the spraying of the system.

The third aspect of the present invention uses a spray gun formed such that the relative angle between the air type spray injection device and the airless type spray injection device is variable, so that the injection is performed from each injection device. It is possible to arbitrarily adjust the angle between the paint spraying directions, and to change the position where the two paint spraying directions intersect to change the collision state of the two paints. The shape of the pattern formed on the patterned resin layer formed with the paint and the degree of unevenness can be varied by spraying the paint onto the inner surface of the casting mold at the intersection of the directions. ,
An artificial marble having various appearances can be obtained.

[Brief description of the drawings]

FIG. 1 shows an example of a process for producing artificial marble of the present invention, and (a) to (e) are cross-sectional views.

FIG. 2 is a side view showing an example of a spray gun used in the present invention.

FIG. 3 is a front view of the same.

FIG. 4 is a plan view of the same.

FIG. 5 is a side view showing an example of the above operation.

FIG. 6 is a plan view showing another example of the above operation.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Patterned resin layer 2 Spray gun 2a, 2b Injection device 3 Casting mold 4 Artificial marble 8 Casting resin composition 14 Paint

──────────────────────────────────────────────────の Continued on the front page (51) Int.Cl. ⁷ Identification symbol FI Theme coat ゛ (Reference) // B29L 9:00 B29L 9:00 31:10 31:10 (72) Inventor Shinji Yamaguchi Kitakyushu, Fukuoka 18-1 Kitakyushu Matsushita Electric Works, Wakamatsu-ku, Ichikawa-shi, Japan (72) Inventor Yoshiaki Tahara 18-ku Yasuse, Wakamatsu-ku, Kitakyushu-shi, Fukuoka 18th Kitakyushu Matsushita Electric Works, Ltd. F-term (reference) 4D075 AA02 AA04 AA38 AA39 CB16 DA29 DC38 EB22 4F033 QA01 QB02Y QB03X QB12Y QB18 QD13 QE06 QK16X QK16Y QK20X QK22X QK22Y QK26X QK26Y RA14 RD01 RD02 RD09 4F204 AA21 AD05 AD11 AF09 EB03 EB03 EB03 EB03 EB03 EB03 EB03 EB03 EB03

Claims (3)

[Claims] 1. After forming a patterned resin layer that expresses a marble pattern by spraying a paint on the inner surface of a casting mold by using both air spray spraying and airless spray spraying, A method for producing artificial marble, characterized by injecting a casting resin composition into a casting mold and molding and curing. 2. The production of artificial marble according to claim 1, wherein the patterned resin layer is formed using a spray gun provided with an air type spray injection device and an airless type spray injection device. Method. 3. The manufacturing of artificial marble according to claim 2, wherein a spray gun formed so that the relative angle between the air type spray injection device and the airless type spray injection device is variable. Method.