JP2002234037A - Method for manufacturing artificial stone and joining method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for manufacturing a high-strength plate mass- shaped artificial stone which shows a beautiful surface appearance and can be easily worked after molding, on account of a non-gel coat technique of a casting process and a joining method by which the joint borderline between the obtained artificial stones is not conspicuous. SOLUTION: The method for manufacturing an artificial stone comprises the first step to add a specified amount of granular pattern-exposed material 12 forming a grained pattern to a matrix 11 composed mainly of a fine- powdered inorganic filler, a curing agent, a curing promoter and a small quantity of colored pigment to an unsaturated polyester resin and remove bubbles from the materials while the material are stirred/mixed using a mixer to obtain a base compound with a proper fluidity, the second step to inject the base compound into a frame 21 and let it be cured at a normal temperature to obtain a primary cured form 22 and the third step to release the primary cured form 22 from the frame 21, then load it into a thermal treatment device and thermally cure to obtain the artificial stone 10.

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 an artificial stone using an unsaturated polyester resin and a method for joining the artificial stone.

[0002]

2. Description of the Related Art Heretofore, in the casting production of artificial stone materials using an unsaturated polyester resin as a binder, the following production methods have been mainly used. All of these methods have the advantage that the appearance after production is clean and that they can be efficiently produced with simple equipment. (1) A method of using natural crushed stone as a main raw material and using an unsaturated polyester resin as a binder to form a natural granite style. (2) A method in which a compound having an unsaturated polyester resin and an inorganic filler is colored with a pigment or the like to express a single color or various patterns. (3) A method in which a special sheet on which a natural marble pattern or an onyx pattern is copied is sealed with an unsaturated polyester resin on the surface of a backup material, and the pattern is displayed transparently.

[0003]

However, in these casting methods, a gel coat for forming a transparent resin film such as a polyester resin is used to form a protective film on the surface of the artificial stone to improve the surface strength. The application to the inner surface is commonly performed. However, forming a protective film on the surface of the artificial stone material has been a factor that causes various problems when processing a formed product. For example, planar processing such as cutting can be easily performed, but much time is required for polishing and chamfering the cut surface after cutting. Also,
When polishing the cut surface, it is necessary to first fill the generated pinholes and then recoat the gel coat.This is an operation requiring labor and skill, and this is a major factor of high cost. Had become. Further, if the recoating of the gel coat is subtly changed, there is also a problem that the aesthetic appearance of the surface is impaired. Therefore, in the casting method, a non-gel coating method in which no gel coat is applied to the surface of the mold is also in practical use.

However, in the casting method, a mold for molding must be prepared using materials such as FRP, metal, glass and the like, and the mold is manufactured using a mold whose shape is standardized like a standard product. In this case, the proportion of the formwork cost in the cost structure is small and the cost can be adequately dealt with.However, if the shape is special, it is necessary to manufacture a dedicated formwork each time, which requires a lot of cost for the formwork. As a result, the production cost rises and the profit becomes unfit. In addition, there are methods such as caulking of silicone resin or pouring the raw material of artificial stone into the joint and polishing after hardening, etc. It was possible and spoiled the aesthetics of structures constructed using artificial stone. The present invention has been made in view of such circumstances, a method for producing a high-strength artificial stone material that is excellent in surface appearance and easy to process after molding by a non-gel coating method of a casting method,
It is another object of the present invention to provide a joining method in which joining boundaries between the obtained artificial stone materials are inconspicuous.

[0005]

According to the first aspect of the present invention, there is provided a method for producing an artificial stone material, comprising the steps of: preparing a fine inorganic filler from 150 to 150 parts by weight of an unsaturated polyester resin;
A base material containing 300 parts by weight, a curing agent of 0.4 to 3.8 parts by weight, a curing accelerator of 0.4 to 1.3 parts by weight, and a small amount of a color pigment, has a predetermined amount for forming a stone-like pattern. The first step of adding a granular pattern material, defoaming while stirring and mixing with a mixer to produce a base compound having a suitable fluidity, and injecting the base compound into a mold and curing at room temperature. A second step of forming a primary hardened body; and a third step of removing the primary hardened body from the mold, charging the heat-treated apparatus, and heat-hardening the same to form an artificial stone material.

[0006] When a curing agent and a curing accelerator are added to an unsaturated polyester resin and mixed well, a polymerization reaction occurs in the unsaturated polyester resin, and the unsaturated polyester resin gradually cures to a hard state. For this reason, inorganic fillers of fine powder for artificially adjusting the color and texture of various stone materials, coloring pigments, and a granular pattern expression material that forms a stone-grain pattern are used as an unsaturated polyester resin and a curing agent. An artificial stone having an arbitrary shape and dimensions can be manufactured by mixing with a curing accelerator to prepare a base compound, pouring into a mold and curing. Furthermore, since the polyester resin is translucent, the internal structure can be seen through, and an artificial stone material having a sense of depth can be obtained. As the curing agent, an organic peroxide-based curing agent, for example, methyl ethyl ketone peroxide having a concentration of 55% can be used. Further, as a curing accelerator for accelerating the curing, for example, cobalt naphthenate having a concentration of 1% can be used. The amount of the curing agent and the curing accelerator to be added varies depending on the type of the curing agent and the curing accelerator, but the amount of the curing agent is 0.1 to 100 parts by weight of the unsaturated polyester.
The range is 4 to 3.8 parts by weight, preferably 0.4 to 3.0 parts by weight, and the curing accelerator is 0.4 to 1.3 parts by weight, preferably 0.4 to 1.0 part by weight. Then, a sufficient pot life can be ensured throughout the summer and winter to cure the unsaturated polyester resin.

The finely divided inorganic filler is used for alleviating shrinkage of the unsaturated polyester resin during curing and for giving the artificial stone a texture, and is used in an amount of 150 to 300 parts by weight based on 100 parts by weight of the unsaturated polyester resin. It is better to add in the range of parts by weight. If the amount of the inorganic filler is less than 150 parts by weight, the effect of alleviating shrinkage during curing of the unsaturated polyester resin is insufficient, and if it exceeds 300 parts by weight, the strength of the artificial stone material is reduced. As the inorganic filler, aluminum hydroxide, calcium carbonate, talc, cold water stone and the like can be used. The coloring pigment is used to impart various colors to the base material portion of the artificial stone material, and a commercially available coloring pigment for polyester can be used. The amount used is small, and the amount of the coloring pigment in the range of 0.04 to 1.3 parts by weight based on 100 parts by weight of the unsaturated polyester resin is sufficient. If the added amount is less than 0.04 parts by weight, the effect of coloring the base material is small, and if it is added in excess of 1.3 parts by weight, the base material becomes excessively colored and the aesthetic appearance and texture of the resulting artificial stone deteriorate. The granular pattern surface material to be added to the base material is to expose the pattern as a stone material on the surface, and by changing the type, shape, color, usage fee, etc. of the pattern surface material used, the artificial stone material Color and texture similar to natural stones.

[0008] In the first step, a saturated polyester resin, a finely divided inorganic filler, a coloring pigment, a curing agent, and a curing accelerator are defoamed while being stirred and mixed by a mixer to form a base material. Then, a predetermined amount of a pattern-exposing material is added and mixed to produce a base compound. By performing defoaming, it is possible to prevent a pinhole-shaped hole from being formed in the base material portion that fills the periphery of the pattern expression material. In the second step, the base compound injected into the mold is cooled to room temperature (for example,
(-30 ° C.) for 4-15 hours to polymerize the unsaturated polyester to form a primary cured product. Third
In the step, the primary cured body is subjected to a heat treatment in an atmosphere at a temperature of, for example, 80 to 85 ° C. for 3 to 4 hours to increase the hardness of the primary cured body to obtain a final cured body. In addition, by heating and hardening, a deep color tone appears, and it has a stone-like tone and a marble tone. Heating temperature is 80 ℃
If it is less than 1, the increase in surface hardness is low, and the surface of the artificial stone is easily flawed, which is not preferable. Heat curing at a temperature exceeding 85 ° C. is not preferable because the primary cured body is deformed. When the temperature of the heat curing treatment is set in the range of 80 to 85 ° C., a sufficient increase in hardness can be caused by treatment for 3 to 4 hours. If the treatment time is less than 3 hours, a sufficient increase in hardness cannot be obtained, and even if the treatment is performed for more than 4 hours, no further increase in hardness occurs and the productivity decreases.
For this reason, it is preferable to set the conditions of the heat curing in a temperature range of 80 to 85 ° C. for 3 to 4 hours.

In the method for manufacturing an artificial stone material according to the first invention, it is preferable to use a colored scale-like alumina oxide-based pattern expression material as the pattern expression material. The dimensions of the flaky alumina oxide pattern expression material are, for example, 0.1 mm in thickness.
０．５0.5 mm and scales of 0.5 to 3 mm can be used. By dispersing the colored scale-like alumina oxide-based pattern expression material in the base material, an artificial stone material having a stone texture can be adjusted. The color of the flaky alumina oxide pattern expression material to be used and the amount to be added are adjusted each time according to the requirements of the stone material to be produced.

In the method of manufacturing an artificial stone material according to the first invention, the pattern-exposing material is made of aluminum hydroxide 10
24 to 26 parts by weight of an unsaturated polyester resin, 0.1 to 1 part by weight of a curing agent, 0.1 to 1 part by weight, based on 0 part by weight
It is preferable to use synthetic particles formed by curing and crushing a mixture containing 0.4 parts by weight and a small amount of a coloring pigment for polyester. As the synthetic particles, those having a size of 0.5 to 3 mm can be used. By using the synthetic grains, an artificial stone material having a stone texture can be adjusted.
Here, when the unsaturated polyester resin is added in excess of 26 parts by weight, the specific gravity of the synthetic particles becomes small, and the synthetic particles float on the upper surface in the base compound injected into the mold. Further, when the unsaturated polyester resin is added so as to be less than 24 parts by weight, the specific gravity of the synthetic particles increases, and the synthetic particles sink to the bottom in the mold. Therefore, the unsaturated polyester resin is defined as 24 to 26 parts by weight with respect to 100 parts by weight of aluminum hydroxide, and the specific gravity of the synthetic particles is adjusted so that the synthetic particles are not present unevenly in the base material. The amount of the coloring pigment is preferably 0.01 to 0.4 parts by weight based on 100 parts by weight of the unsaturated polyester resin. In order to give the optimum color to the synthetic grains, it is difficult to obtain a contrast with the base material when the amount of use is less than 0.01 part by weight, and the contrast with the base material becomes excessive when added more than 0.4 part by weight. Not preferred. As the curing agent, an organic peroxide-based curing agent, for example, methyl ethyl ketone peroxide having a concentration of 55% can be used. Further, as a curing accelerator for accelerating the curing, for example, cobalt naphthenate having a concentration of 1% can be used. The amount of the curing agent and the curing accelerator to be added varies depending on the type of the curing agent and the curing accelerator.
When the amount is in the range of 0.1 to 0.4 parts by weight, the unsaturated polyester resin can be cured while securing a sufficient pot life during summer and winter. The amount of synthetic grains added to the base material is adjusted each time according to the requirements of the stone material to be manufactured. The mixture of the aluminum hydroxide, the unsaturated polyester resin, and the color pigment is cured at room temperature (for example, at 15 to 30 ° C. for 4 to 15 hours), and heat-cured (for example, in an atmosphere at 80 to 85 ° C. for 3 hours). To 4 hours).

According to a second aspect of the present invention, there is provided a method for producing an artificial stone material, wherein 150 to 300 parts by weight of a fine inorganic filler, and 0.4 to 3. 8 parts by weight, curing accelerator 0.4 to 1.3
Defoaming while stirring and mixing a weight part and a small amount of a color pigment with a mixer to produce a base material having an appropriate fluidity.
Steps: 0.4 to 3.8 parts by weight of a curing agent and 100 parts by weight of a curing accelerator with respect to 100 parts by weight of a highly viscous unsaturated polyester resin.
A second step of adding 4 to 1.3 parts by weight and a predetermined amount of a color pigment, defoaming while uniformly stirring and mixing, and adjusting a flowable pattern material for forming an onyx-like pattern;
A third step of forming a base compound in which the fluid pattern material is added in a ratio of 0.02 to 1 part by weight to 0 part by weight and the fluid pattern material is dispersed in the base material in a striped pattern; ,
A fourth step of injecting the base compound into a mold and curing the mixture at room temperature to form a primary cured product; and removing the primary cured product from the mold, charging the cured product into a heat treatment apparatus, and heating and curing the artificial cured product. And a fifth step of forming a stone.

As the highly viscous unsaturated polyester resin used for the flowable picture material, for example, one having a viscosity of 1500 to 2000 millipascal seconds can be used. Further, the color and the amount of the coloring pigment are adjusted each time according to the requirements of the stone material to be manufactured. To 100 parts by weight of the base material adjusted in advance, 0.02 to 1 part by weight of the flowable pattern material is added, and, for example, several arbitrary portions in the container are stirred for several seconds each by a manual stirrer. Since the viscosity of the flowable pattern material is, for example, 3 to 4 times greater than the viscosity of the base material, the base compound will be in an inhomogeneous mixed state only by stirring a few arbitrary places for several seconds each with a manual stirrer. The flowable picture material added to the base material is always mixed in a striped manner. Therefore, by changing the size of the spout and the injection speed when injecting the base compound into the mold, it is possible to control the form of dispersion of the fluid picture material in the mold.
For example, when the injection speed is low, the interval between the stripes is wide, and when the injection speed is high, the interval between the stripes is narrow. Fluid pattern materials existing in a striped pattern in the mold have higher viscosity than the base compound and do not mix with each other. By performing the curing treatment in this state, the striped fluid picture material can be cured and fixed in the base compound.

In the method for producing an artificial stone according to the first and second aspects of the present invention, when the base material is produced in the first step,
It is preferable to add 0.5 to 2 parts by weight of an antifoaming agent to 100 parts by weight of the base material. By adding 0.5 to 2 parts by weight of an antifoaming agent, an unsaturated polyester resin, a finely divided inorganic filler, a coloring pigment, a curing agent, a curing accelerator, and a pattern expression material (or a flowable pattern material) are added. The air entrained at the time of mixing can be efficiently removed in a short time. Here, as the defoaming agent, a commercially available defoaming agent for polyester can be used.

According to one embodiment of the present invention, there is provided a method for joining artificial stone materials, which comprises mixing and stirring an unsaturated polyester resin, a finely divided inorganic filler, a curing agent, a curing accelerator, and a small amount of a color pigment. While a defoaming is performed on the base material, a predetermined amount of granular pattern expression material for forming a stone-grain pattern,
Or, an artificial stone material obtained by injecting a predetermined amount of a flowable pattern material forming an onyx pattern into a mold, curing the mixture at room temperature, removing the mold from the mold, and heating and curing the mold. Wherein the same inorganic filler as the fine powder used in the artificial stone is used in an amount of 120 to 150 parts by weight, based on 100 parts by weight of an unsaturated polyester resin having high viscosity and thixotropic properties, 0.4 to 3.8 parts by weight, 0.4 to 1.3 parts by weight of a curing accelerator, and a small amount of the same coloring pigment as the coloring pigment used in the artificial stone are added, and defoaming while stirring and mixing with a mixer. Performing the first step of producing an adhesive, filling the gap provided between the artificial stone materials to be joined with the adhesive,
A second step of curing the filled adhesive while maintaining the gap at a predetermined interval; and a third step of polishing and removing the cured adhesive that has adhered to the surface of the artificial stone material.

Since an unsaturated polyester resin having high viscosity and thixotropy is used for the adhesive, it is necessary to fill an adhesive supply device such as a squeezer or the like and extrude the adhesive so that a necessary amount of the gap between the artificial stones is removed. An adhesive can be filled.
In addition, since the extruded adhesive has thixotropic properties and does not flow unless an external force is applied, the gap filled with the adhesive is maintained at a predetermined interval, and until the curing of the adhesive is started, the adhesive is applied to the gap portion. The adhesive can be securely fixed. By setting the composition of the adhesive closer to the composition of the artificial stone material to be joined, the cured joining layer has a structure close to the base material of the artificial stone material, and the joining boundary becomes inconspicuous. For this reason, the same amount of the inorganic filler 120 to 150 as the inorganic filler of the fine powder used for the artificial stone is used with respect to 100 parts by weight of the unsaturated polyester resin having high viscosity and thixotropic properties.
Parts by weight, 0.4 to 3.8 parts by weight of a curing agent, 0.
It was configured to add 4 to 1.3 parts by weight and a small amount of the same coloring pigment as the coloring pigment used for the artificial stone. If the amount of the inorganic filler is less than 120 parts by weight, a structure close to that of the base material of the artificial stone cannot be obtained. If the amount of the inorganic filler exceeds 150 parts by weight, the adhesion to the artificial stone decreases. Therefore, the usage fee of the inorganic filler is specified as 120 to 150 parts by weight.

[0016]

DESCRIPTION OF THE PREFERRED EMBODIMENTS Next, embodiments of the present invention will be described with reference to the accompanying drawings to provide an understanding of the present invention. Here, FIG. 1 is a cross-sectional view showing a state in which a base compound is injected into a mold in the method for manufacturing an artificial stone according to the first embodiment of the present invention, and FIG. 2 is a sectional view showing a second embodiment of the present invention. FIG. 3 is a cross-sectional view showing a state in which a base compound is injected into a mold in the method for manufacturing an artificial stone material, and FIG. 3 is a state in which a base compound is injected into the form in a method for manufacturing an artificial stone according to the third embodiment of the present invention. 4 (a), 4 (b), and 4 (c) are cross-sectional views of an artificial stone manufactured by applying the method of manufacturing an artificial stone according to the first to third embodiments of the present invention, respectively. FIG. 5 and FIG. 5 are cross-sectional views showing an arrangement before joining of artificial stones to which the method for joining artificial stones according to one embodiment of the present invention is applied, and FIG. 6 is joining of artificial stones to which the method for joining artificial stones is applied. It is sectional drawing explaining the state at the time.

A method for manufacturing an artificial stone according to the first embodiment of the present invention will be described in detail. 100 parts by weight of an unsaturated polyester resin having a viscosity of about 500 millipascal-seconds, 150 to 300 parts by weight of aluminum hydroxide having a particle size of 100 μm or less and a whiteness of 96 or more, which is an example of an inorganic filler, to adjust the color to be expressed Colored pigment of 0.
04 to 1.3 parts by weight, 0.4 to 3.8 parts by weight (preferably 0.4 to 3.0 parts by weight) of 55% concentration methyl ethyl ketone, which is an example of a curing agent, and an example of a curing accelerator A base material 11 containing 0.4 to 1.3 parts by weight (preferably 0.4 to 1.0 parts by weight) of a 1% concentration of cobalt naphthenate
Of a commercially available polyester antifoaming agent, which is an example of an antifoaming agent, is added at a ratio of 0.5 to 2 parts by weight based on 100 parts by weight of the base material 11. 5-3m
The colored scale-like alumina oxide-based pattern expression material 12 is added in an amount capable of expressing the desired stone tone, and defoaming is performed by, for example, stirring and mixing for 10 minutes using a rotary mixer as an example of a mixer. Then, the base compound is adjusted (the above is the first step).

As shown in FIG. 1, a base compound having an appropriate fluidity is adjusted and poured into a mold 21 coated with a commercially available wax-based release agent.
It is left to cure for a time, and the mold is removed to obtain the primary cured body 22 (the above is the second step). Here, as the mold 21, for example, a bottom plate 23 formed of any one of granite, tempered glass, and stainless steel plate on a flat surface, and a stainless steel square steel tube 24 on the side can be disassembled and disassembled. Can be used. The primary cured body 22 is removed from the mold 21 and is charged into an air bath, which is an example of a heat treatment apparatus, at a temperature of 80 to 85.
The artificial stone 10 is manufactured by holding at 3 ° C. for 3 to 4 hours and curing by heating (third step).

As shown in FIG. 4A, an artificial stone 10 to which the method of manufacturing an artificial stone according to the first embodiment of the present invention is applied includes a base material 11 forming a matrix of the artificial stone 10, And a colored scale-like alumina oxide-based pattern expression material 12 dispersed in a base material 11. Because it is the flaky alumina oxide pattern surface material 12, the flaky alumina oxide surface material 12 has various directions with respect to the surface 13 of the artificial stone material 10 depending on the situation when it is poured into the mold 21. Turn around. For example, a flaky alumina oxide pattern expression material 12
When the bottom surface is arranged along the surface 13 of the artificial stone material 10, the scale portion of the flaky alumina oxide pattern expression material 12 is exposed, and the thickness portion of the flake alumina oxide pattern expression material 12 is the artificial stone material 10. If it arrange | positions along the surface 13 of this, the thickness part of the scale-like alumina-oxide pattern surface material 12 will be exposed. For this reason, various textures can be formed. Since the base material 11 has translucency,
Scale-like alumina oxide pattern surface material 1 dispersed inside
2 can also be seen through the surface 13 to express a sense of depth and a sense of quality.

Next, a method of manufacturing an artificial stone according to a second embodiment of the present invention will be described in detail. First, a method of adjusting the synthetic grains 16 as a pattern surface material will be described.
Viscosity is 50 for 100 parts by weight of aluminum hydroxide.
Unsaturated polyester resin of about 0 millipascal seconds 24-
26 parts by weight, 0.1 to 1 part by weight of 55% -concentration methylacetyl ketone as an example of a curing agent, and 0.1 to 0.4 part by weight of 1% -cobalt naphthenate as an example of a curing accelerator Parts, and 0.01 to 0.4 parts by weight of a coloring pigment for adjusting the color shade to be expressed, and mixing with a rotary mixer, for example, for 10 minutes to adjust the mixture.
What was formed into a foil shape of 10 mm was cured by leaving it at room temperature for 4 to 15 hours. The hardened plate is crushed with a crusher to obtain 0.1%.
The synthetic grain 16 is manufactured by setting the particle diameter to 5 to 3 mm.

100 parts by weight of an unsaturated polyester resin having a viscosity of about 500 millipascal-second, 150 to 300 parts by weight of aluminum hydroxide having a particle size of 100 μm or less and a whiteness of 96 or more, which is an example of an inorganic filler, 0.04 to 1.3 parts by weight of a coloring pigment for adjustment, and 0.4 to 3.8 parts by weight (preferably 0.4 to 3.0 parts by weight) of 55% concentration methyl ethyl ketone as an example of a curing agent. ), 0.4 to 1.3 parts by weight (preferably 0.4 to 1. 1 part) of 1% concentration cobalt naphthenate, which is an example of a curing accelerator.
(0 parts by weight), a commercially available defoamer for polyester, which is an example of an antifoaming agent, is added at a ratio of 0.5 to 2 parts by weight based on 100 parts by weight of the base material 15. The synthesized particles 16 are added in such an amount that the desired stone tone can be expressed, and the mixture is stirred and mixed with a rotary mixer for, for example, 10 minutes to produce a base compound (the above is the first step). As shown in FIG. 2, the prepared base compound was poured into a mold 21 coated with a commercially available wax-based mold release agent.
It is left to cure for about 15 hours, and is demolded to obtain a primary cured body 25 (the above is the second step). The primary hardened body 25 is removed from the mold 21, inserted into an air bath as an example of a heat treatment apparatus, held at a temperature of 80 to 85 ° C. for 3 to 4 hours, and heated and hardened (third step). To manufacture.

As shown in FIG. 4B, an artificial stone 14 to which the method of manufacturing an artificial stone according to the second embodiment of the present invention is applied includes a base material 15 forming a matrix of the artificial stone 14, And synthetic grains 16 dispersed in the base material 15. Since the synthetic grains 16 have a crushed shape, any of the synthetic grains 16 can be clearly exposed on each surface 17 of the artificial stone 14. Since the base material 15 has a light-transmitting property, the synthetic grains 16 dispersed inside the base material 15 also have a surface 17.
It is possible to see through, and to express a sense of depth and heavy feeling.

Next, a method of manufacturing an artificial stone according to a third embodiment of the present invention will be described in detail. Viscosity is 5
Unsaturated polyester resin of about 10 millipascal seconds 10
0 parts by weight, particle size 100 μm, which is an example of an inorganic filler
Aluminum hydroxide 150 to 3 having a whiteness of 96 or more
00 parts by weight, 0.04 to 1.3 parts by weight of a coloring pigment for adjusting a desired color tone, 55% which is an example of a curing agent
0.4-3.8 parts by weight (preferably 0.4-3.0 parts by weight) of methyl ethyl ketone peroxide, and 0.4-1.3% by weight of 1% cobalt naphthenate as an example of a curing accelerator.
A base material 19 containing 100 parts by weight of a commercially available defoamer for polyester, which is an example of a defoamer, is added to the base material 19 containing 100 parts by weight of ２2 parts by weight, and defoaming with a rotary mixer while stirring and mixing for, for example, 10 minutes to produce a base material 19.
First step). Also, for 100 parts by weight of a highly viscous unsaturated polyester resin having a viscosity of about 1500 to 2000 millipascal seconds, 0.4 to 3.8 parts by weight of methyl ethyl ketone (55% concentration) as an example of a curing agent (preferably 0.4 to 3.0 parts by weight), 1% which is an example of a curing accelerator
A concentration of 0.4 to 1.3 parts by weight of cobalt naphthenate (preferably 0.4 to 1.0 parts by weight), and a coloring pigment for polyester for adjusting the color shade to be expressed, are added by a rotary mixer. Defoaming is performed while stirring and mixing uniformly for 20 minutes to produce the fluid picture material 26 (the above is the second step).

Next, with respect to 100 parts by weight of the base material 19,
The prepared flowable pattern material 26 having a viscosity of, for example, about 90 g / cms is added at a ratio of 0.02 to 1 part by weight, and, for example, several arbitrary places in the container are stirred with a manual stirrer for about several seconds, respectively. A base compound in a state in which the flowable picture material 27 added in 19 is mixed in a stripe form is produced (the above is the third step). As shown in FIG. 3, the obtained base compound is poured into a mold 21. At this time, form 2
The injection is performed while arbitrarily adjusting the diameter of the spout when injecting the base compound into the base compound 1 and further changing the injection speed. Thereby, the interval and the thickness of the stripe pattern formed by the flowable picture material 26 can be adjusted. The fluid pattern material 26 existing in a striped pattern in the formwork 21 is
Since the viscosity is higher than that of the above, they do not mix with each other, and the state of the striped pattern formed at the time of injection is maintained as it is. Therefore, when the mold is left at room temperature for 4 to 15 hours for curing and demolding in this state, the primary cured body 27 in which the striped pattern formed when injected is exposed is obtained (the above is the fourth step). The primary cured body 27 is released from the mold 21 and is charged into an air bath, which is an example of a heat treatment apparatus, and is heated to a temperature of 80 to
The artificial stone 18 is manufactured by holding at 85 ° C. for 3 to 4 hours and curing by heating (fifth step).

As shown in FIG. 4C, the artificial stone 18 to which the method of manufacturing an artificial stone according to the third embodiment of the present invention is applied includes a base material 19 forming a matrix of the artificial stone 18, A striped portion formed when the flowable pattern material 26 mixed in the base material 19 is poured into the mold 21 has a striped portion 20 which is hardened. Since the striped portions 20 are formed in a matrix in a complex manner, and the matrix has a light-transmitting property, it is possible to manufacture an onyx-like artificial stone material 18 having a very deep, three-dimensional, and heavy texture. Can be.

The method for joining artificial stone materials according to one embodiment of the present invention will be described in detail. Here, the method of joining artificial stone materials according to the present embodiment employs an adhesive 3 used for joining.
2 (see FIG. 6) and the joining operation of joining the artificial stone materials 10 with the adhesive 32.
And the joining operation will be described in detail.
The adjustment of the adhesive 32 was performed as follows. For example, with respect to 100 parts by weight of a highly viscous and thixotropic unsaturated polyester resin having a viscosity of about 1500 to 2000 centipoise, 120 to 150 parts by weight of the same inorganic filler as the fine powder inorganic filler used for the artificial stone material, 0.04 to 1.3 parts by weight of the same color pigment as the color pigment used for the stone, 0.4 to 3.8 parts by weight of methyl ethyl ketone (55% concentration) as an example of a curing agent (preferably 0.4 to 3.8 parts by weight)
3.0 parts by weight), and 0.4 to 1.3 parts by weight (preferably 0.4 to 1.0 parts by weight) of 1% cobalt naphthenate, which is an example of a curing accelerator, in an example of a mixer. It is produced by defoaming with a certain rotary mixer while stirring and mixing for, for example, 20 minutes (first step). In order to completely remove bubbles, an operation of putting the adjusted adhesive in a container, placing it on a vibrating table, applying vibration, and causing internal bubbles to float on the surface and remove them may be added.

The joining operation was performed as follows. First, the corner portion of the joint surface 28 of the artificial stone 10 manufactured by applying the method of manufacturing an artificial stone according to the above embodiment is lightly ground with, for example, a # 320 file to obtain a yarn surface 29.
To form Next, the joining surface 28 and stains near the joining surface 28 are removed with an organic solvent such as a lacquer thinner. Furthermore,
A block-shaped clamp fixing jig 30 made of, for example, a steel piece is spotted on one surface of the artificial stone 10 with, for example, an instant adhesive. The artificial stone 10 is placed on a flat joining table 31 with the surface to which the clamp fixing jig 30 is adhered as the upper surface,
The interval between the joint surfaces 28 of the artificial stone 10 is, for example, 2 to 3 m.
m. The adhesive 32 filled in a supply device such as a squeezer is filled in a gap provided between the joint surfaces 28 of the artificial stone 10. After the adhesive 32 is filled, the clamps 33 are attached between the clamp fixing jigs 30 and tightened until the gap becomes, for example, 0.5 to 1 mm. By reducing the space between the gaps provided between the joint surfaces 28 of the artificial stone 10, the joint surfaces 2 of the artificial stone 28 are reduced.
8 and the adhesive 32 can be improved.
By reducing the gap, the excess adhesive 32 flows out to the upper surface side. In this state, the mixture is left to cure at room temperature for 4 to 15 hours. The curing can also be performed by maintaining the composition in a heated atmosphere at 40 to 50 ° C. for 1 to 4 hours (second step). After the curing is completed, the adhesive 32 that has flowed out to the surface and has been cured is polished and removed (third step).

The embodiment of the present invention has been described above.
The present invention is not limited to this embodiment,
For example, although aluminum hydroxide was used as the inorganic filler of the fine powder, calcium carbonate, talc, and dolomite can also be used. As the defoaming agent, a commercially available defoaming agent for polyester was used, but it is also possible to use a commercially available defoaming surfactant containing no silicone in combination. In addition, when defoaming by adding an antifoaming agent, the defoaming treatment can be performed more effectively by stirring and mixing under reduced pressure.

[0029]

According to the first and second aspects of the present invention,
The method for producing an artificial stone material according to any one of the items 3 and 5, wherein a stone-like pattern is formed on a base material containing an unsaturated polyester resin, a finely divided inorganic filler, a curing agent, a curing accelerator, and a small amount of a coloring pigment. A first step of adding a fixed amount of a granular pattern material, defoaming while stirring and mixing with a mixer to produce a base compound having an appropriate fluidity, and injecting the base compound into a mold and curing at room temperature. And a third step of forming a primary cured body by molding, and a third step of removing the primary cured body from the mold, loading into a heat treatment apparatus, and heat-curing to form an artificial stone material. It is possible to produce an artificial stone material having high strength, excellent surface appearance, and easy post-processing by the non-gel coat method.

In particular, in the method for producing an artificial stone material according to the second aspect, since a colored flaky alumina oxide pattern material is used as the pattern material, a monochromatic, marble,
An artificial stone material having various pattern patterns such as stone patterns can be manufactured without dimensional restrictions.

In the method for producing an artificial stone material according to the third aspect, as the pattern-exposing material, 24-26 parts by weight of an unsaturated polyester resin and 0.1-1 part by weight of a curing agent are added to 100 parts by weight of aluminum hydroxide. , Curing accelerators 0.1 to 0.
Since synthetic particles formed by hardening and crushing a mixture containing 4 parts by weight and a small amount of a coloring pigment are used, an artificial stone material having a stone-like pattern can be manufactured at low cost without dimensional restrictions. . Further, since the synthetic grains are in a crushed form, the shape of the synthetic grains appearing on the cut surface is clear, and the appearance as an artificial stone is improved.

According to a fourth aspect of the present invention, there is provided a method for producing an artificial stone material, comprising the steps of: mixing an unsaturated polyester resin, a finely divided inorganic filler, a curing agent, a curing accelerator, and a small amount of a color pigment. Defoaming while stirring and mixing in the first step to produce a base material having appropriate fluidity, and uniformly adding a high-viscosity unsaturated polyester resin, a curing agent, a curing accelerator, and a predetermined amount of a coloring pigment. A second step of preparing a flowable pattern material for forming an onyx pattern by defoaming while stirring and mixing, and adding a flowable pattern material in a ratio of 0.02 to 1 part by weight to 100 parts by weight of the base material; A third step of forming a base compound in which a fluid pattern material is dispersed in a matrix in a striped pattern, and a fourth step of injecting the base compound into a mold and curing at room temperature to form a primary cured body. , Removal of primary cured product from mold Because and a fifth step of the artificial stone cured by heating was charged into a heat treatment apparatus, very steric Onyx tone artificial stone with depth can be easily manufactured.

In particular, in the method for producing artificial stone according to the fifth aspect, the defoamer is added in an amount of 0.5 to 2 parts by weight to 100 parts by weight of the base material when the base material is produced in the first step. In addition, the defoaming is sufficiently performed, and a uniform artificial stone material can be manufactured to the inside. For this reason, the work of burying the pinholes appearing on the cut surface is eliminated, the processing time can be reduced, and the manufacturing cost can be reduced.

In the method for joining artificial stones according to the sixth aspect, an unsaturated polyester resin having high viscosity and thixotropic properties, the same inorganic filler as the inorganic filler of the fine powder used for the artificial stones, a curing agent, and a curing accelerator. Between the first step of producing the adhesive by adding a small amount of the same coloring pigment as the coloring agent used for the artificial stone and the artificial stone, and performing defoaming while stirring and mixing with a mixer, and the artificial stone to be bonded to each other A second step of filling the provided gap with an adhesive, curing the filled adhesive while maintaining the gap at a predetermined interval, and a third step of polishing and removing the hardened adhesive attached to the surface of the artificial stone material; Since it has a
It is possible to manufacture complex deformed artificial stones easily and inexpensively by joining artificial stones manufactured using existing molds without using dedicated molds for complex deformed artificial stones. .

[Brief description of the drawings]

FIG. 1 is a cross-sectional view showing a state in which a base compound is injected into a mold in a method for manufacturing an artificial stone according to a first embodiment of the present invention.

FIG. 2 is a cross-sectional view showing a state in which a base compound has been injected into a mold in a method for manufacturing an artificial stone according to a second embodiment of the present invention.

FIG. 3 is a perspective sectional view showing a state in which a base compound is injected into a mold in a method for manufacturing an artificial stone according to a third embodiment of the present invention.

FIGS. 4 (a), (b) and (c) are cross-sectional views of artificial stones manufactured by applying the artificial stone manufacturing methods according to the first to third embodiments of the present invention, respectively.

FIG. 5 is a cross-sectional view showing an arrangement of artificial stones before joining to which the method for joining artificial stones according to one embodiment of the present invention is applied.

FIG. 6 is a cross-sectional view illustrating a state at the time of joining artificial stone materials to which the method of joining artificial stone materials is applied.

[Explanation of symbols]

10: artificial stone, 11: base material, 12: scale-like alumina oxide pattern expression material, 13: surface, 14: artificial stone, 15:
Base material, 16: synthetic grain, 17: surface, 18: artificial stone, 1
9: base material, 20: striped portion, 21: formwork, 22: primary cured body, 23: bottom plate portion, 24: stainless steel square tube, 25: 1
Primary cured product, 26: Flowable picture material, 27: Primary cured product, 2
8: joining surface, 29: thread surface, 30: jig for fixing clamp,
31: bonding stand, 32: adhesive, 33: clamp

──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. ⁷ Identification symbol FI Theme coat ゛ (Reference) C08F 2/44 C08F 2/44 A 283/01 283/01 // B29K 67:00 B29K 67:00 105: 16 105: 16 C04B 111: 54 C04B 111: 54 F term (reference) 4F204 AA41 AB03 AB11 AB12 AB16 EA03 EA04 EB01 EB28 EE12 EF01 EF02 EK17 EW02 EW06 EW24 EW31 4J011 GA05 GB07 PA07 PA13 PA29 PA34 P3022 CA20 CA34 CA36 CB04 CB08 CC02 CD01

Claims (6)

[Claims] 1. A fine inorganic filler of 150 to 300 parts by weight, a curing agent of 0.4 to 3.8 parts by weight, and a curing accelerator of 0.4 to 1.3 parts by weight based on 100 parts by weight of the unsaturated polyester resin.
A predetermined amount of a granular pattern-forming material for forming a stone-grain pattern is added to the base material containing parts by weight and a small amount of color pigment, and defoaming is performed while stirring and mixing with a mixer to obtain a suitable fluidity. A first step of forming a base compound having the same, a second step of injecting the base compound into a mold and curing at room temperature to form a primary cured body, and removing the primary cured body from the mold and heat treating A third step of loading into an apparatus and heat-curing to form an artificial stone material. 2. The method for producing an artificial stone material according to claim 1, wherein a colored flaky alumina oxide pattern expression material is used as the pattern expression material. 3. The method for producing an artificial stone material according to claim 1, wherein said pattern-exposing material is aluminum hydroxide.
24 to 26 parts by weight of an unsaturated polyester resin, 0.1 to 1 part by weight of a curing agent, 0.1 to 1 part by weight, based on 0 part by weight
A method for producing an artificial stone material, comprising using synthetic particles formed by curing and crushing a mixture containing 0.4 parts by weight and a small amount of a coloring pigment. 4. A fine powder inorganic filler of 150 to 300 parts by weight, a curing agent of 0.4 to 3.8 parts by weight, and a curing accelerator of 0.4 to 1.3 parts per 100 parts by weight of the unsaturated polyester resin.
Defoaming while stirring and mixing a weight part and a small amount of a color pigment with a mixer to produce a base material having an appropriate fluidity.
Steps: 0.4 to 3.8 parts by weight of a curing agent and 100 parts by weight of a curing accelerator with respect to 100 parts by weight of a highly viscous unsaturated polyester resin.
A second step of adding 4 to 1.3 parts by weight and a predetermined amount of a color pigment, defoaming while uniformly stirring and mixing, and adjusting a flowable pattern material for forming an onyx-like pattern;
A third step of forming a base compound in which the fluid pattern material is added in a ratio of 0.02 to 1 part by weight to 0 part by weight and the fluid pattern material is dispersed in the base material in a striped pattern; ,
A fourth step of injecting the base compound into a mold and curing the mixture at room temperature to form a primary cured product; and removing the primary cured product from the mold, charging the cured product into a heat treatment apparatus, and heating and curing the artificial cured product. 5. A method for producing an artificial stone, comprising: a fifth step of forming a stone. 5. The method for manufacturing an artificial stone material according to claim 1, wherein when the base material is formed in the first step, an antifoaming agent is used for 100 parts by weight of the base material. 0.5
A method for producing an artificial stone material, characterized by adding about 2 parts by weight. 6. A stone-like pattern is formed on a base material produced by performing defoaming while stirring and mixing an unsaturated polyester resin, a finely divided inorganic filler, a curing agent, a curing accelerator, and a small amount of a color pigment. A base compound prepared by mixing a predetermined amount of a granular pattern material to be formed or a predetermined amount of a flowable pattern material forming an onyx pattern is poured into a mold, cured at room temperature, and then removed from the mold. A method of joining artificial stone materials obtained by molding and heat-curing, with respect to 100 parts by weight of an unsaturated polyester resin having high viscosity and thixotropic properties,
120 to 150 parts by weight of the same inorganic filler as the finely divided inorganic filler used in the artificial stone material, and a hardener of 0.4 to 3.
8 parts by weight, 0.4 to 1.3 parts by weight of a hardening accelerator, and a small amount of the same coloring pigment as the coloring pigment used in the artificial stone are added, and the mixture is defoamed while being stirred and mixed by a mixer to remove the adhesive. A first step of manufacturing, and a second step of filling the gap provided between the artificial stone materials joined to each other with the adhesive, curing the filled adhesive while maintaining the gap at a predetermined interval, and And polishing the adhesive that has adhered to the surface of the artificial stone and hardened, and a third step of polishing and removing the adhesive.