JP2002321231A - Method for manufacturing artificial marble - Google Patents

Abstract

PROBLEM TO BE SOLVED: To enhance the impact strength of artificial marble, to eliminate necessity for suppressing the lowering of the strength of the artificial marble by forming a woody reinforcing plate or FRP reinforcing layer on the rear surface of the artificial marble, to make the artificial marble lightweight by reducing the thickness thereof and to enhance the appearance capacity of the artificial marble. SOLUTION: In manufacturing the artificial marble by molding an artificial marble resin composition, which is prepared by compounding additives such as a filler, an internal release agent, a curing agent or the like with a thermosetting resin, to cure the same, an inorganic needle filler is added to and compounded with the artificial marble resin composition.

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 used as furniture members or building materials.

[0002]

2. Description of the Related Art Conventionally, an artificial marble resin composition containing a thermosetting resin and additives such as a filler, a reinforcing material, an internal release agent, and a curing agent is injected into a desired casting mold. It is known to form artificial marble by heat curing.

As a thermosetting resin as a raw material for producing artificial marble, a polyester resin, a vinyl ester resin, an acrylic resin and the like have been conventionally used.
Artificial marble molded products utilizing these are widely used for washbasins, kitchen counters, bathtubs, washbasins, and so on.

Usually, in order to increase the impact resistance of artificial marble products, the amount of glass fiber added as a reinforcing material is increased. However, when the blending amount of the glass fiber is increased, the flow of the artificial marble pattern or the pattern is remarkably hindered, the mixing and dispersion becomes uneven, or the fuzz of the glass fiber occurs on the product surface. ,
Since it is not possible to obtain a product with uniform quality and a product with good appearance performance, there is a limit in improving the impact resistance by using glass fiber.

For this purpose, a wooden reinforcing plate is provided on the back of artificial marble, or FRP
2. Description of the Related Art A reinforcing layer of (fiber reinforced plastics) is provided or a product is made thicker.

[0006]

However, in the above case, the processing time for reinforcing the back surface of the artificial marble is increased and the cost is increased, and the product weight is increased due to the difficulty in reducing the thickness. The burden on product operation and construction was heavy.

The present invention has been made in view of the above-mentioned problems of the prior art, and it is an object of the present invention to improve the impact resistance of artificial marble. The present invention provides a method for manufacturing artificial marble which enables a product to be thinner and lighter without forming a wooden reinforcing plate or a FRP reinforcing layer to compensate for a decrease in strength, and furthermore, has excellent appearance performance. It is in.

[0008]

According to the present invention, there is provided an artificial marble resin composition in which a thermosetting resin is blended with a filler and additives such as an internal release agent and a curing agent. In the method for producing artificial marble obtained by molding and curing this artificial marble resin composition, the artificial marble resin composition is characterized by adding an inorganic needle-like filler to the artificial marble resin composition. By doing so, the impact resistance of the artificial marble molded product can be improved by adding and blending the inorganic needle filler, and the resulting artificial marble exhibits excellent impact resistance (toughness). Also,
Wooden reinforcement plate or FRP on the back of artificial marble as before
It is not necessary to form a reinforcing layer to compensate for the decrease in strength, and the appearance performance is improved because glass fiber is not added and blended as in the conventional case.

[0009]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment of the present invention will be described below.

The artificial marble of the present embodiment is obtained by mixing an artificial marble resin composition containing a thermosetting resin and additives such as a filler, a reinforcing material, an internal mold release agent, and a curing agent. It is characterized by adding and blending an inorganic needle filler into the artificial marble resin composition when producing by molding and curing.

As the inorganic acicular filler, a mineral filler or a single crystal fiber filler is used.

In this case, wollastonite is used as the mineral filler. This wollastonite is classified as a mineral filler among the inorganic needle-like fillers, and is represented by CaSiO ₃ (wollastonite) in its general formula, but is usually SiO ₂ , CaO. Fe ₂
O _3, are those constituted by chemical components such as A1 ₂ O _3, MgO. This has recently attracted attention as a material that replaces conventional asbestos (asbestos) from the standpoint of carcinogenicity.

The wollastonite having an average aspect ratio (length / diameter) of 3 to 300 is used. If the average aspect ratio is less than 3, the shape approaches a granular shape, the effect as a fiber component is reduced, and the effect of improving the impact resistance by adding is difficult to obtain, and if it is 300 or more, the uniform dispersibility of the addition is poor. Becomes, the distribution of wollastonite in the artificial marble resin composition becomes non-uniform, and it is not possible to obtain a uniform impact strength improvement of the obtained product,
That is, the quality is largely varied. Furthermore, wollastonite in the present invention has an average fiber length of 6 to 500 μm and an average fiber diameter of 2 to 500 μm.
A material having a property of 100 μm is used. As in the case of the average aspect ratio, the average fiber length is 6 μm.
m, or an average fiber diameter of less than 2 μm, the length of the fiber is too short, or the fiber diameter is too small to improve the impact resistance, and the average fiber length is 500 μm or more, Alternatively, when the average fiber diameter is 100 μm or more, the fiber length is too long or the fiber diameter is too large, so that the uniform dispersibility in addition and mixing is deteriorated, and the uniform impact strength of the product is not improved. .

Next, a case where a single crystal fiber filler is used as the inorganic needle filler will be described. Basic magnesium sulfate whiskers, calcium silicate whiskers, potassium titanate whiskers, and aluminum borate whiskers used in the present invention are each classified as a single crystal fiber-based filler, and each has the following chemical components. It is represented. That is, basic magnesium sulfate whisker = MgSO ₄ .5Mg (OH) ₂ .3H
₂ O, calcium silicate whisker = 6CaO · 6SiO ₂
Is represented by H ₂ O, and the potassium titanate whisker is
Although represented by the general formula “K ₂ O · nTiO ₂ ”, in the present invention, potassium hexatitanate whisker with n = 6,8 = K ₂ O
· 6TiO _2, 8 potassium titanate whisker = K ₂ O · 8
TiO ₂ is used. The aluminum borate whiskers _{= 9A1 2 O 3 · 2B 2} O 3.

For the same reason as in the case of wollastonite, in the case of a single crystal fiber-based filler, one having an average aspect ratio of 10 to 300, and an average fiber length of 0.5 to 500 μm. And the average fiber diameter is 0.05 to 1
A material having a property of 0 μm is used. In addition, the single crystal fiber-based filler is 0.5 to 15 parts based on the amount of the thermosetting resin.
It is used by adding 0%. As the single crystal fiber-based filler, any of basic magnesium sulfate whiskers, calcium silicate whiskers, potassium titanate whiskers, and aluminum borate whiskers are used.

As the thermosetting resin, one or a mixture of two or more of polyester resin, vinyl ester resin and acrylic resin is used.

As the polyester resin, thermosetting ones (or both) of an unsaturated dibasic acid such as maleic anhydride and a saturated dibasic acid such as phthalic anhydride are subjected to a condensation reaction with glycols. It has a unsaturated bond and an ester bond in the molecule.
Usually, a styrene monomer, an acrylic monomer, or the like is blended as a cross-linking agent in this resin.
Although what is called an unsaturated polyester resin is used, its form is not particularly limited.

As the vinyl ester resin, a bisphenol type vinyl ester resin, a novolak type vinyl ester resin, or a mixture of both can be used. Here, the bisphenol-type vinyl ester resin is an addition reaction product of a bisphenol-type epoxy resin and an acid, and each has a reactive unsaturated group only at both ends. As the bisphenol type epoxy resin, bisphenol A type, bisphenol AD type,
Various types such as bisphenol S type and bisphenol F type can be used. Usually, the vinyl ester resin contains a styrene monomer, an acrylic monomer, or the like as a crosslinking agent, but the form is not particularly limited.

As the acrylic resin, a thermosetting type is usually called a methyl methacrylate monomer, or a polyfunctional acrylic monomer or a prepolymer, or a so-called acrylic syrup composed of a mixture of two or more kinds of polymers. Although it is used, its form is not particularly limited.

When a mixture of two or more of the above-mentioned polyester resin, vinyl ester resin and acrylic resin is used, the properties of each resin and the interaction with the filler,
Alternatively, due to the interaction with the inorganic needle-like filler to be added or blended, an optimal blending suitable for the desired product quality is required, but the blending amount is not particularly limited.

In the present invention, the above-mentioned inorganic needle filler is added to the artificial marble resin composition. Usually, 0.5 to 150% of the amount of the thermosetting resin in the artificial marble resin composition is added and used. The impact resistance of the artificial marble molded product is improved by the addition and blending of the inorganic needle filler, which is determined by the properties and the amount of the inorganic needle filler. If the amount of addition is less than 0.5% with respect to the amount of the thermosetting resin, the effect is hardly obtained, and
If the content is 150% or more, although the effect is obtained, the viscosity of the artificial marble resin composition itself is extremely increased by addition, and the fluidity is deteriorated, and it becomes very difficult to inject the artificial marble resin composition into a casting mold. Therefore, it is more preferable to set it to about 150%. Of course, if the difficulty of the injection is not a problem, it may be 150% or more, and it is not particularly limited.

As the filler to be filled in the thermosetting resin, one or a mixture of two or more of aluminum hydroxide, silica, and glass powder is used.
The compounding amount of the filler is preferably 100 to 300 parts by weight based on 100 parts by weight of the thermosetting resin. If the amount is less than this range, the impact resistance of the product is excellent but the heat resistance cannot be sufficiently exhibited. If it exceeds this range, the heat resistance is excellent, but the impact strength may decrease.

The smaller the particle size of the filler is, the more the impact resistance of the artificial marble can be improved. However, the viscosity of the artificial marble resin composition sharply increases and the production tends to become difficult. In the present invention, the lower limit of the average particle size is set to 5 μm. On the other hand, when the particle size of the filler increases,
Although the viscosity of the artificial marble resin composition decreases and there is no problem in production, the impact strength of the artificial marble product tends to decrease. Therefore, in the present invention, the upper limit of the average particle size is 5
It is set to 0 μm. Furthermore, the use of a filler which has been subjected to a silane coupling treatment on the surface of the filler in advance can improve the adhesiveness between the filler and the resin and further improve the impact resistance of the artificial marble product. Becomes

The inorganic needle-like filler composed of the above-mentioned mineral filler or single-crystal fiber filler can be used alone or in a mixture of two or more of them. (Wollastonite) is also possible. Also, as in the case of the filler, the use of an inorganic needle-like filler whose surface has been subjected to a silane coupling treatment in advance can improve the adhesion between the inorganic needle-like filler and the resin, and the artificial marble Since the impact resistance of the product can be further improved, an inorganic needle-like filler which has been surface-treated in advance can also be used.

Further, a curing agent is added to the artificial marble resin composition. Examples of the curing agent include 1,1,3,3-tetramethylbutylperoxy-2-ethylhexaate and t
-Hexyl peroxy 2-ethylhexanoate and the like can be used. The mixing ratio of the curing agent is, for example, in the case of a vinyl ester resin, the total amount of the resin and the crosslinking agent is 10%.
It is preferably 0.5 to 5 parts by weight with respect to 0 parts by weight.

The artificial marble resin composition may further contain an ultraviolet absorber, a viscosity reducing agent, a release agent, a glass fiber, a colorant, and the like. As a viscosity reducing agent, for example, "W996" manufactured by BYK, as a release agent, for example, "Separ" (trade name, manufactured by Chukyo Yushi), and as a glass fiber, for example, a product number "RESO3X-BM" manufactured by Nippon Sheet Glass. Can be used. As the ultraviolet absorber, benzotriazole-based, triazine-based, benzoate-based, salylate-based, cyanoacrylate-based oxalic anilide-based, and benzophenone-based ones can be used.

The artificial marble resin composition is prepared by blending these blends in a predetermined ratio and mixing and stirring with a stirrer or the like.

Next, in producing artificial marble from the artificial marble resin composition, the artificial marble resin composition whose composition has been adjusted is subjected to vacuum defoaming under reduced pressure of about 30 to 50 Torr. The defoamed artificial marble resin composition is released from the reduced pressure state, poured into a mold having a predetermined shape, and heated at a temperature of 50 to 110 ° C. for 30 to 120 minutes. By heating, the copolymerization reaction between the reactive unsaturated group in the thermosetting resin in the artificial marble resin composition and the polymerizable monomer in the resin proceeds, and the curing and molding of the artificial marble resin composition It can be performed.

The artificial marble obtained in this way has excellent impact resistance, and it is not necessary to form a wooden reinforcing plate or an FRP reinforcing layer on the back surface of the artificial marble to supplement the strength. , High impact resistance (toughness) can be exhibited, and the product made of this artificial marble can be made thinner and lighter,
Also, artificial marble having excellent appearance can be obtained.

Such an artificial marble molded product can be easily commercialized into a wash counter, a kitchen counter, a bathtub, a wash bowl and the like.

[0031]

The present invention will be described below in detail with reference to examples. (Example 1) A polyester resin (Polymer 5450, manufactured by Takeda Pharmaceutical Co., Ltd.) was used as a thermosetting resin, and aluminum hydroxide (H-manufactured by Showa Denko KK) was used as a filler with respect to 100 parts by weight of the resin. 310 Average particle size 1
7 μm) was added in an amount of 160 parts by weight. In addition, basic magnesium sulfate whisker having an aspect ratio of 10 to 15, an average fiber length of 7 to 10 μm, and an average fiber diameter of 0.5 to 1.0 μm (Mosh Heidi manufactured by Ube Materials Co., Ltd.)
Was mixed with the thermosetting resin in an amount of 40 parts by weight (40%). Further, 3.2 parts by weight of a curing agent (Percure HO manufactured by NOF Corporation) was added to obtain an artificial marble composition for casting. This is applied under reduced pressure of 20 Torr for 60 minutes.
It was subjected to vacuum defoaming treatment, poured into a mold for forming a flat plate having a thickness of 12 mm, and heated at a mold temperature of 100 ° C. for 120 minutes to cure the artificial marble composition to obtain an artificial marble molded product. Example 2 A vinyl ester resin (Prominate P-311 manufactured by Takeda Pharmaceutical Co., Ltd.) was used as a thermosetting resin, and aluminum hydroxide (Showa Denko KK) was used as a filler with respect to 100 parts by weight of the resin. H-308B, average particle size 8 μm) was blended in an amount of 150 parts by weight. In this, the aspect ratio is 10-20, the average fiber length is 1-5 μm,
A calcium silicate whisker having an average fiber diameter of 0.1 to 0.5 μm (Zonoheidi manufactured by Ube Materials Co., Ltd.)
60 parts by weight (60%) were added to the thermosetting resin. Furthermore, a curing agent (Percure H manufactured by NOF Corporation)
O) was added by 3.5 parts by weight to obtain an artificial marble composition.
This was vacuum-defoamed under a reduced pressure of 20 Torr for 80 minutes, poured into a mold for forming a 12 mm thick flat plate, and heated at a mold temperature of 105 ° C. for 110 minutes to cure the artificial marble composition. A marble molding was obtained. (Example 3) Acrylic syrup resin (AC-02, manufactured by Nippon Fellows Co., Ltd.) was used as a thermosetting resin, and silica (CRYSTALITE M, manufactured by Tatsumori Co., Ltd.) was used as a filler with respect to 100 parts by weight of the resin. -3K average particle diameter 20 μm) was blended in an amount of 145 parts by weight. In this, the aspect ratio is 20-30, the average fiber length is 10-30 μm,
Aluminum borate whiskers having an average fiber diameter of 0.5 to 1.0 μm (Albolex Y manufactured by Shikoku Chemicals Co., Ltd.)
Was mixed with the above thermosetting resin in an amount of 50 parts by weight (50%). Further, 1.6 parts by weight of a curing agent (Perkadox 16 manufactured by Kayaku Akzo Co., Ltd.) was added to obtain an artificial marble composition. This is subjected to vacuum defoaming treatment under reduced pressure of 20 Torr for 60 minutes, poured into a mold for forming a flat plate having a thickness of 12 mm, and heated at a mold temperature of 103 ° C. for 120 minutes to cure the artificial marble composition. A marble molding was obtained. (Example 4) Acrylic syrup resin (AC-02, manufactured by Nippon Fellow Co., Ltd.) was used as a thermosetting resin, and silica (CRYSTAL1TEM, manufactured by Tatsumori Co., Ltd.) was used as a filler with respect to 100 parts by weight of the resin. -3K average particle size of 20 µm) was blended in an amount of 160 parts by weight. In this, the aspect ratio is 20-30, the average fiber length is 10-30 μm,
An aluminum borate whisker (Albolex YS3A manufactured by Shikoku Chemicals Co., Ltd.) having an average fiber diameter of 0.5 to 1.0 μm and surface-treated with an aminosilane-based coupling agent is applied to the thermosetting resin. 55 parts by weight (55%) were blended. Furthermore, a curing agent (Kakuyaku Akzo Co., Ltd.)
1.8% by weight of Perkadox 16) was added to obtain an artificial marble composition. This is reduced to 6 under reduced pressure of 20 Torr.
Vacuum defoaming treatment was performed for 0 minutes, and the mixture was poured into a mold for forming a flat plate having a thickness of 12 mm and heated at a mold temperature of 103 ° C. for 120 minutes to cure the artificial marble composition to obtain an artificial marble molded product. (Example 5) As a thermosetting resin, a vinyl ester resin (Ripoxy R-804, manufactured by Showa Polymer Co., Ltd.) and a polyester resin (Polyal 5250, Takeda Pharmaceutical Co., Ltd.)
Was mixed at a mixing ratio of 60/40, and 100 parts by weight of the mixed resin was mixed with 1 part of aluminum hydroxide (H-320 manufactured by Showa Denko KK, average particle size: 10 μm) as a filler.
50 parts by weight were blended. In addition, the aspect ratio is 30-3
5. The average fiber length is 10 to 20 μm and the average fiber diameter is 0.
40 parts by weight (40%) of 3-0.6 μm potassium hexatitanate whisker (Tismo N manufactured by Otsuka Chemical Co., Ltd.) was mixed with the thermosetting resin. Further, 3.5 parts by weight of a curing agent (Percure HO manufactured by NOF CORPORATION) was added to obtain an artificial marble composition, which was subjected to vacuum defoaming treatment under reduced pressure of 20 Torr for 55 minutes to obtain a 12 mm thick flat plate. Is injected into a mold for molding and the mold temperature is set to 100 ° C at 110 ° C.
After heating for a minute, the artificial marble composition was cured to obtain an artificial marble molded product. (Example 6) As a thermosetting resin, a vinyl ester resin (Lipoxy R-804, manufactured by Showa Polymer Co., Ltd.) and an acrylic syrup resin (XE924-1, Mitsui Chemicals, Inc.)
Was mixed at a mixing ratio of 75/25, and 100 parts by weight of the mixed resin were mixed with aluminum hydroxide (H-320, manufactured by Showa Denko KK, average particle size: 10 μm) as a filler, and glass powder (Nippon Frit (Japan Frit)). GF-2-30
A (average particle size: 30 μm) was mixed at a ratio of 80/20 to 155 parts by weight. In addition, the aspect ratio is 30
Potassium octa titanate whisker (Tismo D, manufactured by Otsuka Chemical Co., Ltd.) having a mean fiber length of 10 to 20 μm and a mean fiber diameter of 0.3 to 0.6 μm is 70 Parts by weight (70%) were blended. Further, 4.0 parts by weight of a hardening agent (Percure WO manufactured by NOF Corporation) was added to obtain an artificial marble composition. This is 20 Torr
Vacuum defoaming treatment under reduced pressure for 50 minutes, pouring into a mold for forming a flat plate having a thickness of 12 mm, heating at a mold temperature of 110 ° C. for 100 minutes to cure the artificial marble composition, and molding the artificial marble Product was obtained. (Comparative Examples 1 to 6) Artificial marble molded products were obtained with the same composition and the same molding conditions as in Examples 1 to 6, except that no single crystal fiber-based filler was added to the artificial marble composition. (Evaluation Test) Each of the above Examples 1 to 6 and Comparative Examples 1 to
With respect to the artificial marble molded product obtained in 6, the Charpy impact strength (kJ / m ² ) was measured, and the surface smoothness, the pattern unevenness, and the appearance performance of the transparency were visually evaluated and judged. Table 1 shows the results.

[0032]

[Table 1]

Example 7 As a thermosetting resin, a polyester resin (Polymer 5450 manufactured by Takeda Pharmaceutical Co., Ltd.)
Using, as a filler for 100 parts by weight of this resin,
Aluminum hydroxide (H-310 manufactured by Showa Denko KK)
(Average particle size: 17 μm) was blended in an amount of 150 parts by weight. The aspect ratio is 10 to 11 and the average fiber length is 140μ.
m, wollastonite having an average fiber diameter of 12 μm (KH-30 manufactured by Kawairon Mining Co., Ltd.) was blended in an amount of 45 parts by weight (45%) based on the thermosetting resin. Further, 3.0 parts by weight of a curing agent (Percure HO manufactured by NOF Corporation) was added to obtain an artificial marble composition for casting. This is 20 Torr
Vacuum defoaming treatment under a reduced pressure of 60 minutes, pour into a mold for forming a 12 mm thick flat plate, heat the mold temperature at 100 ° C. for 120 minutes to cure the artificial marble composition, and form the artificial marble Product was obtained. Example 8 A vinyl ester resin (Prominate P-311 manufactured by Takeda Pharmaceutical Co., Ltd.) was used as a thermosetting resin, and aluminum hydroxide (Showa Denko KK) was used as a filler with respect to 100 parts by weight of the resin. H-308B, average particle size 8 μm) was blended in an amount of 150 parts by weight. To this, 63 parts by weight of wollastonite (KH-450, manufactured by Kawatetsu Mining Co., Ltd.) having an aspect ratio of 11, an average fiber length of 35 μm, and an average fiber diameter of 3.3 μm were added to the thermosetting resin. (63%). Further, 3.5 parts by weight of a curing agent (Percure HO manufactured by NOF Corporation) was added to obtain an artificial marble composition. This was vacuum-defoamed under a reduced pressure of 20 Torr for 80 minutes, poured into a mold for forming a 12 mm thick flat plate, and heated at a mold temperature of 105 ° C. for 110 minutes to cure the artificial marble composition. A marble molding was obtained. (Example 9) An acrylic syrup resin (AC-02, manufactured by Nippon Fellow Co., Ltd.) was used as a thermosetting resin, and silica (CRYSTAL1TEM, manufactured by Tatsumori Co., Ltd.) was used as a filler with respect to 100 parts by weight of the resin. -3K average particle size of 20 μm) was mixed in an amount of 140 parts by weight. Wollastonite having an aspect ratio of 6, an average fiber length of 400 μm, and an average fiber diameter of 70 μm (KH, manufactured by Kawairon Mining Co., Ltd.)
-120) was blended in an amount of 50 parts by weight (50%) with respect to the thermosetting resin. Furthermore, a curing agent (Kakuyaku Akzo Co., Ltd.)
1.6% by weight of Perkadox 16) was added to obtain an artificial marble composition. This is reduced to 6 under reduced pressure of 20 Torr.
Vacuum defoaming treatment was performed for 0 minutes, and the mixture was poured into a mold for forming a flat plate having a thickness of 12 mm and heated at a mold temperature of 103 ° C. for 120 minutes to cure the artificial marble composition to obtain an artificial marble molded product. (Example 10) As a thermosetting resin, a vinyl ester resin (Ripoxy R-804 manufactured by Showa Polymer Co., Ltd.) and a polyester resin (Polymer 525 manufactured by Takeda Pharmaceutical Co., Ltd.)
0) in a mixing ratio of 60/40, and this mixed resin 10
Aluminum hydroxide (H-320 manufactured by Showa Denko KK, average particle size: 10 μm) as a filler with respect to 0 parts by weight
Was blended in 160 parts by weight. The average aspect ratio is 7, the average fiber length is 180 μm, and the average fiber diameter is 25 μm.
Wollastonite (A type manufactured by Kawairon Mining Co., Ltd.)
Was mixed with the thermosetting resin in an amount of 30 parts by weight (30%). Further, 3.0 parts by weight of a curing agent (Percure HO manufactured by NOF Corporation) was added to obtain an artificial marble composition. This was vacuum-defoamed under reduced pressure of 20 Torr for 55 minutes, poured into a mold for forming a 12 mm thick flat plate, and heated at a mold temperature of 110 ° C. for 100 minutes to harden the artificial marble composition. A marble molding was obtained. (Example 11) As a thermosetting resin, a vinyl ester resin (Ripoxy R-804 manufactured by Showa Polymer Co., Ltd.) and an acrylic syrup resin (XE924 manufactured by Mitsui Chemicals, Inc.)
1) was mixed at a mixing ratio of 75/25, and the mixed resin 10
Aluminum hydroxide (H-320 manufactured by Showa Denko KK, average particle size: 10 μm) as a filler with respect to 0 parts by weight.
And glass powder (GF-2 manufactured by Nippon Frit Co., Ltd.)
-30 parts by weight of -30A (average particle size: 30 µm) was mixed at 80/20 to obtain 155 parts by weight. In addition, the aspect ratio is 3, the average fiber length is 35 μm, and the average fiber diameter is 12 μm.
Wollastonite (C-10 manufactured by Kawairon Mining Co., Ltd.)
With 100 parts by weight (100 parts by weight) based on the thermosetting resin.
%). Further, 4.0 parts by weight of a curing agent (Percure WO manufactured by NOF Corporation) was added to obtain an artificial marble composition. This was vacuum-defoamed under reduced pressure of 20 Torr for 50 minutes, poured into a mold for forming a 12 mm thick flat plate, and heated at a mold temperature of 110 ° C. for 100 minutes to cure the artificial marble composition. A marble molding was obtained. (Comparative Examples 7 to 11) Artificial marble molded products were obtained with the same composition and the same molding conditions as in Examples 7 to 11, except that wollastonite was not added to the artificial marble composition. (Evaluation Test) Each of Examples 7 to 11 and Comparative Example 7
For each of the artificial marble molded products obtained in Nos. 1 to 11, the Charpy impact strength (kJ / m ² ) was measured, and the surface smoothness, pattern unevenness, and the appearance performance of transparency were evaluated and judged visually. Table 2 shows the results.

[0034]

[Table 2]

[0035]

As described above, according to the first aspect of the present invention, there is provided an artificial marble resin composition obtained by blending a thermosetting resin with additives such as a filler, an internal mold release agent, and a curing agent. In the method for producing an artificial marble obtained by molding and curing this artificial marble resin composition, an inorganic needle filler is added and blended into the artificial marble resin composition. The impact resistance of the molded article can be improved, and the resulting artificial marble exhibits excellent impact resistance (toughness). Therefore, a wooden reinforcing plate or a reinforcing layer made of FRP is not formed on the back surface of the artificial marble to compensate for the decrease in strength as in the conventional case, and the weight can be reduced by reducing the thickness of the product. Since no fibers are added and blended, artificial marble having excellent appearance performance can be obtained.

──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. ⁷ Identification code FI Theme coat ゛ (Reference) C08K 7/04 C08K 7/04 C08L 33/00 C08L 33/00 63/10 63/10 67/06 67 / 06 101/00 101/00 // (C04B 26/18 C04B 26/18 14:38 14:38 C Z 14:36 14:36 14:22 14:22 14:04) 14:04 Z B29K 31:00 B29K 31:00 33:00 33:00 67:00 67:00 101: 10 101: 10 103: 04 103: 04 105: 16 105: 16 B29L 31:00 B29L 31:00 C04B 111: 12 C04B 111: 12 111: 20 111: 20 F term (reference) 4F204 AA21 AA24 AA41 AA43 AB03 AB11 AF09 AH44 AR12 FA01 FB01 FB21 FF06 FQ01 4J002 BG021 CD201 CF211 DE147 DE186 DG046 DJ006 DJ017 DK006 DL007 FA066 FD016 FD017 GL02

Claims (13)

[Claims] 1. An artificial marble resin composition obtained by blending a thermosetting resin with additives such as a filler, an internal mold release agent and a curing agent, and molding and curing the artificial marble resin composition. A method for producing artificial marble, characterized by adding an inorganic needle filler to an artificial marble resin composition. 2. The method for producing artificial marble according to claim 1, wherein the inorganic acicular filler is a mineral filler or a single crystal fiber filler. 3. The method for producing artificial marble according to claim 1, wherein the mineral filler is wollastonite. 4. The method for producing artificial marble according to claim 2, wherein the average aspect ratio of wollastonite is 3 to 300. 5. The wollastonite having an average fiber length of 6
The method for producing artificial marble according to claim 2, wherein the average marble diameter is 2 to 100 m. 6. The method for producing artificial marble according to claim 2, wherein the single crystal fiber-based filler is a basic magnesium sulfate whisker. 7. The method for producing artificial marble according to claim 2, wherein the single crystal fiber-based filler is calcium silicate whisker. 8. The method for producing artificial marble according to claim 2, wherein the single crystal fiber filler is potassium titanate whisker. 9. The method for producing artificial marble according to claim 2, wherein the single crystal fiber-based filler is aluminum borate whisker. 10. An average aspect ratio of the single-crystal fiber filler is 10 to 300, and an average fiber length is 0.5.
The method for producing artificial marble according to claim 2, wherein the average marble diameter is 0.05 to 10 m. 11. The thermosetting resin is a polyester resin,
2. The composition according to claim 1, wherein the resin is one or a mixture of two or more of a vinyl ester resin and an acrylic resin.
The method for producing the artificial marble described. 12. The production of artificial marble according to claim 1, wherein the filler for the thermosetting resin is one or a mixture of two or more of aluminum hydroxide, silica, and glass powder. Method. 13. A filler having a particle size of 5 to thermosetting resin.
The method for producing artificial marble according to claim 1, wherein the thickness is 50 µm.