JP2003127150A - Method for producing artificial marble - Google Patents
Method for producing artificial marbleInfo
- Publication number
- JP2003127150A JP2003127150A JP2001329897A JP2001329897A JP2003127150A JP 2003127150 A JP2003127150 A JP 2003127150A JP 2001329897 A JP2001329897 A JP 2001329897A JP 2001329897 A JP2001329897 A JP 2001329897A JP 2003127150 A JP2003127150 A JP 2003127150A
- Authority
- JP
- Japan
- Prior art keywords
- artificial marble
- resin
- resin composition
- pattern material
- molding
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Withdrawn
Links
Landscapes
- Casting Or Compression Moulding Of Plastics Or The Like (AREA)
Abstract
Description
【0001】[0001]
【発明の属する技術分野】本発明は、家具の部材や建材
として用いられる人造大理石の製造方法に関するもので
ある。BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing artificial marble used as a furniture member or a building material.
【0002】[0002]
【従来の技術】従来から熱硬化性樹脂と充填剤、柄材、
補強材、内部離型剤、硬化剤などの添加物を配合した人
造大理石成形用樹脂組成物を所望の注型金型に注入し、
加熱硬化させることによって人造大理石を形成すること
が知られている。2. Description of the Related Art Conventionally, thermosetting resins, fillers, handle materials,
Reinforcing an artificial marble molding resin composition containing additives such as a reinforcing material, an internal release agent, and a curing agent into a desired casting mold,
It is known to form artificial marble by heating and hardening.
【0003】人造大理石を製造するための原料となる熱
硬化性樹脂としては、従来よりポリエステル樹脂、ビニ
ルエステル樹脂、アクリル樹脂などが用いられている。
これらを活用した人造大理石の成形品は、洗面カウンタ
ー、キッチンカウンター、浴槽、洗面ボールなどに広く
利用されている。As a thermosetting resin which is a raw material for producing artificial marble, polyester resins, vinyl ester resins, acrylic resins and the like have been conventionally used.
Artificial marble moldings that make use of these are widely used in bathroom counters, kitchen counters, bathtubs, and washbasins.
【0004】通常、高意匠柄やグラニット調柄の人造大
理石製品を得るために形状や色調が異なる数種の柄材が
配合された人造大理石成形用樹脂組成物を得ることが行
われている。特に、より自然感のある高級柄として大粒
柄の添加配合が求められている。しかしながら、大粒柄
になればなるほど、その柄材をコンパウンドに添加配合
して均一に分散することが困難となる。即ち、コンパウ
ンドに添加配合した柄材は、混練しても柄材同士がくっ
ついた形のままなかなかバラバラにならずコンパウンド
内での均一分散性が出来ない状態になってしまってい
た。[0004] Usually, in order to obtain an artificial marble product having a high design pattern or a granite pattern, it has been practiced to obtain an artificial marble molding resin composition containing several types of pattern materials having different shapes and color tones. In particular, it is required to add and mix a large grain pattern as a high quality pattern having a more natural feeling. However, the larger the grain pattern, the more difficult it is to add and mix the pattern material to the compound and to disperse it uniformly. That is, the pattern material added and compounded in the compound did not easily disintegrate even when kneaded, and the pattern materials could not be uniformly dispersed in the compound.
【0005】このような状態で得られた人造大理石成形
品は、柄の固まった部分とそうでない部分とが散在して
求める柄表現とはほど遠いものとなっていた。The artificial marble molded product obtained in such a state is far from the desired pattern expression in which the solidified portion and the non-solidified portion are scattered.
【0006】また、柄材がくっついたまま成形される
と、柄材同士の間にコンパウンド成分が介在しないた
め、ちょうど人造大理石成形品の内部にクラック(割
れ)が入った形となり、極端に製品強度が低下してしま
うという問題があった。Further, if the pattern materials are molded while they are stuck to each other, the compound component does not exist between the pattern materials, so that the artificial marble molded article will have a crack (crack) inside, which is extremely extreme. There was a problem that the strength was reduced.
【0007】そこで、大粒柄材を添加して均一に分散
し、製品強度の低下を招かない人造大理石の製造方法が
切望されているのが現状である。Under the circumstances, therefore, there is a strong demand for a method for producing artificial marble in which a large grain pattern material is added and uniformly dispersed so as not to reduce the product strength.
【0008】[0008]
【発明が解決しようとする課題】本発明は上記の点に鑑
みてなされたものであり、人造大理石成形用樹脂組成物
に大粒柄材を均一に分散混練配合でき、しかも製品強度
を低下させることなく高級感のある高意匠柄あるいはグ
ラニット柄の人造大理石の製造方法を提供することを課
題とするものである。SUMMARY OF THE INVENTION The present invention has been made in view of the above points, and it is possible to uniformly disperse and knead a large grained patterning material into an artificial marble molding resin composition and to reduce the product strength. It is an object of the present invention to provide a method for producing an artificial marble having a high design pattern or a granite pattern with a high quality.
【0009】[0009]
【課題を解決するための手段】上記課題を解決するため
に本発明に係る人造大理石の製造方法は、熱硬化性樹脂
に充填剤、内部離型剤、硬化剤などの添加物を配合した
コンパウンドに柄材を添加して人造大理石成形用樹脂組
成物を得て、この人造大理石成形用樹脂組成物を成形硬
化させて人造大理石を得る人造大理石の製造方法におい
て、大粒柄材をあらかじめ重合性の溶剤で混ぜ合わせた
後、コンパウンドと混練して大粒柄材入り人造大理石成
形用樹脂組成物としたことを特徴とするものである。こ
のような方法を採用することで、人造大理石成形用樹脂
組成物に大粒柄材を添加配合しても柄材同士がくっつく
ことがなくて均一に分散混練配合できるものである。ま
た、大粒柄材間にコンパウンド成分が介在しないという
ようなことがなくて製品強度の低下を招かない。In order to solve the above-mentioned problems, the method for producing an artificial marble according to the present invention is a compound in which additives such as a filler, an internal mold release agent and a hardening agent are mixed with a thermosetting resin. In the method for producing an artificial marble in which the artificial marble molding resin composition is obtained by adding a pattern material to the artificial marble molding resin, the artificial marble molding resin composition is molded and cured to obtain an artificial marble. It is characterized in that it is mixed with a solvent and then kneaded with a compound to obtain a resin composition for artificial marble molding containing a large grain pattern material. By adopting such a method, even if a large-sized pattern material is added and mixed to the artificial marble molding resin composition, the pattern materials do not stick to each other and can be uniformly kneaded and mixed. Further, the compound component does not exist between the large grain pattern materials, and the product strength is not deteriorated.
【0010】また、熱硬化性樹脂に充填剤、内部離型
剤、硬化剤などの添加物を配合したコンパウンドに柄材
を添加して人造大理石成形用樹脂組成物を得て、この人
造大理石成形用樹脂組成物を成形硬化させて人造大理石
を得る人造大理石の製造方法において、大粒柄材をあら
かじめ熱硬化性樹脂で混ぜ合わせた後、コンパウンドと
混練して大粒柄材入り人造大理石成形用樹脂組成物とし
たことを特徴とするものであってもよい。このような方
法を採用することで、人造大理石成形用樹脂組成物に大
粒柄材を添加配合しても柄材同士がくっつくことがなく
て均一に分散混練配合できるものである。また、大粒柄
材間にコンパウンド成分が介在しないというようなこと
がなくて製品強度の低下を招かない。Further, a pattern material is added to a compound in which a thermosetting resin is mixed with additives such as a filler, an internal mold release agent, and a curing agent to obtain a resin composition for artificial marble molding. In a method for producing an artificial marble by molding and curing a resin composition for use in manufacturing, an artificial marble molding resin composition containing a large-sized pattern material after being mixed with a large-sized pattern material in advance with a thermosetting resin and kneaded with a compound. It may be a thing characterized by being a thing. By adopting such a method, even if a large-sized pattern material is added and mixed to the artificial marble molding resin composition, the pattern materials do not stick to each other and can be uniformly kneaded and mixed. Further, the compound component does not exist between the large grain pattern materials, and the product strength is not deteriorated.
【0011】そして、熱硬化性樹脂がポリエステル樹
脂、ビニルエステル樹脂、アクリル樹脂の内の1種類、
あるいは2種類以上の混合物であることが好ましいもの
である。The thermosetting resin is one of polyester resin, vinyl ester resin and acrylic resin,
Alternatively, a mixture of two or more kinds is preferable.
【0012】また、大粒柄材の平均厚みが0.1〜3.
0mmで且つ平均粒径1mm以上であることが好ましい
ものである。Also, the average thickness of the large grain pattern material is 0.1-3.
It is preferable that the diameter is 0 mm and the average particle diameter is 1 mm or more.
【0013】[0013]
【発明の実施の形態】以下、本発明を添付図面に示す実
施形態に基づいて説明する。BEST MODE FOR CARRYING OUT THE INVENTION The present invention will be described below based on the embodiments shown in the accompanying drawings.
【0014】本発明の人造大理石の製造方法は、熱硬化
性樹脂に充填剤、内部離型剤、硬化剤などの添加物を配
合したコンパウンドに柄材を添加して人造大理石成形用
樹脂組成物を得て、この人造大理石成形用樹脂組成物を
成形硬化させて人造大理石を得る人造大理石の製造方法
において、大粒柄材をあらかじめ重合性の溶剤(架橋
剤)あるいは熱硬化性樹脂で混ぜ合わせた後、コンパウ
ンドと混練して大粒柄材入り人造大理石成形用樹脂組成
物とし、この大粒柄材入り人造大理石成形用樹脂組成物
を注型用金型内に注入して加熱硬化し、人造大理石成形
品を得るものである。The method for producing an artificial marble of the present invention is a resin composition for forming an artificial marble in which a pattern material is added to a compound in which a thermosetting resin is mixed with additives such as a filler, an internal release agent and a curing agent. In the method for producing an artificial marble in which the artificial marble molding resin composition is obtained by molding and curing, the large grain handle material is mixed with a polymerizable solvent (crosslinking agent) or a thermosetting resin in advance. After that, it is kneaded with a compound to obtain a resin composition for artificial marble molding with a large grain pattern material, and this resin composition for artificial marble molding with a large grain pattern material is poured into a casting mold and heat-cured to form an artificial marble molding. You get the goods.
【0015】本発明に用いる大粒柄材は、その平均厚み
を0.1〜3.0mmとするが、0.1mm以下では本
発明の方法でも柄材同士のくっつきが強力で、なかなか
個々がばらけて均一になりにくく、逆に3.0mm以上
になると本発明の方法を用いなくても個々がばらけて均
一分散できるからである。また、平均粒径を1mm以上
とするが、1mm以下では本発明の方法を用いなくても
個々がばらけて均一分散できないからである。The large-diameter pattern material used in the present invention has an average thickness of 0.1 to 3.0 mm, but if the average particle thickness is 0.1 mm or less, the pattern materials adhere strongly to each other even in the method of the present invention, and the individual pattern materials are easily separated. It is difficult for the particles to be uniform, and conversely, when the particle diameter is 3.0 mm or more, the particles are dispersed and uniformly dispersed without using the method of the present invention. Further, the average particle size is set to 1 mm or more, but if the average particle size is 1 mm or less, the particles are dispersed and cannot be uniformly dispersed without using the method of the present invention.
【0016】これらの大粒柄材をコンパウンドに混ぜ込
む前に、予め重合性溶剤(架橋剤)又は熱硬化性樹脂と
混ぜ合わせる。混ぜ合わせる方法としては、重合性溶剤
(架橋剤)又は熱硬化性樹脂を入れた容器の中へ撹拌し
ながら大粒柄材を徐々に投入していく方法で行うことが
できる。Before mixing these large grain handle materials into the compound, they are previously mixed with a polymerizable solvent (crosslinking agent) or a thermosetting resin. As a method of mixing, a large grain handle material can be gradually added into a container containing a polymerizable solvent (crosslinking agent) or a thermosetting resin while stirring.
【0017】混ぜ合わせる重合性溶剤(架橋剤)又は熱
硬化性樹脂は単独系であるため、通常の樹脂組成物に添
加する場合に比べ極端に低粘度で行うことができる。こ
の操作によって大粒柄材は個々がばらばらになって分散
し、個々の大粒柄材の表面全体が重合性溶剤(架橋剤)
又は熱硬化性樹脂で濡れて覆われることになる。このよ
うな状態のままコンパウンドに添加して混練りしても良
く、大粒柄材の表面が濡れた状態であれば、過剰の重合
性溶剤(架橋剤)又は熱硬化性樹脂を取り除いて(液切
りして)添加混練りしてもよい。Since the polymerizable solvent (crosslinking agent) or the thermosetting resin to be mixed is a single system, it can be carried out with an extremely low viscosity as compared with the case where it is added to a usual resin composition. By this operation, the large grain pattern material is disintegrated and dispersed, and the entire surface of each large grain pattern material is a polymerizable solvent (crosslinking agent).
Alternatively, it will be wet and covered with a thermosetting resin. In such a state, it may be added to the compound and kneaded. If the surface of the large grain pattern material is wet, remove the excess polymerizable solvent (crosslinking agent) or thermosetting resin (liquid It may be cut and added and kneaded.
【0018】このように表面全体が濡れた状態で添加さ
れた大粒柄材は、コンパウンド内で混練りされて容易に
均一に分散することになる。また、例えコンパウンドの
中でその一部がくっついた状態になって分散している場
合でも、くっついている大粒柄材の界面に重合性溶剤
(架橋剤)又は熱硬化性樹脂が介在しているため、その
後の加熱硬化の操作によって重合反応が進行して樹脂組
成物との架橋反応がおこるため、従来のように柄材間に
クラックは入った形となるようなことがなくなるもので
ある。As described above, the large grain pattern material added while the entire surface is wet is kneaded in the compound and easily dispersed uniformly. Also, even if a part of the compound is dispersed in a state of sticking in the compound, a polymerizable solvent (crosslinking agent) or thermosetting resin is present at the interface of the large-sized handle material that is stuck. Therefore, since the polymerization reaction proceeds by the subsequent heat-curing operation to cause a crosslinking reaction with the resin composition, cracks are not formed between the handle materials as in the conventional case.
【0019】大粒柄材を構成する樹脂組成物の熱硬化性
樹脂と、この大粒柄材を添加して得られる人造大理石成
型用樹脂組成物を構成する熱硬化性樹脂とは同じ種類の
ものを用いるのが好ましく、熱硬化性樹脂はポリエステ
ル樹脂、ビニルエステル樹脂、アクリル樹脂の単独、あ
るいはこれらの2種類以上の混合系で用いることができ
る。The thermosetting resin of the resin composition constituting the large grain pattern material and the thermosetting resin constituting the resin composition for artificial marble molding obtained by adding the large grain pattern material are of the same kind. It is preferable to use, and the thermosetting resin may be a polyester resin, a vinyl ester resin, an acrylic resin alone, or a mixed system of two or more of these.
【0020】ポリエステル樹脂としては、熱硬化性のも
のとして無水マレイン酸のような不飽和二塩基酸および
無水フタル酸のような飽和二塩基酸とグリコール類とを
縮合反応させて合成され、分子内に不飽和結合とエステ
ル結合を有するものである。また、通常、この樹脂には
架橋剤としてスチレンモノマー、アクリルモノマー等が
配合されていて、いわゆる不飽和ポリエステル樹脂と称
されるものを用いるが、その形態は特に限定されるもの
ではない。The polyester resin is a thermosetting resin, which is synthesized by subjecting an unsaturated dibasic acid such as maleic anhydride and a saturated dibasic acid such as phthalic anhydride to a condensation reaction with glycols to produce an intramolecular compound. It has an unsaturated bond and an ester bond. Usually, a styrene monomer, an acrylic monomer, etc. are blended as a cross-linking agent in this resin, and a so-called unsaturated polyester resin is used, but its form is not particularly limited.
【0021】ビニルエステル樹脂としては、ビスフェノ
ール型ビニルエステル樹脂あるいはノボラック型ビニル
エステル樹脂あるいはその両方を混合して用いることが
できる。The vinyl ester resin may be a bisphenol type vinyl ester resin, a novolac type vinyl ester resin, or a mixture of both.
【0022】ここで、ビスフェノール型ビニルエステル
樹脂は、ビスフェノール型エポキシ樹脂と酸との付加反
応物であって、いずれも両末端のみに反応性不飽和基を
有するものである。また、ビスフェノール型エポキシ樹
脂としては、ビスフェノールA型、ビスフェノールAD
型、ビスフェノールS型、ビスフェノールF型等の各種
のものを用いることができる。また、通常、このビニル
エステル樹脂には架橋剤としてスチレンモノマー、アク
リルモノマー等が配合されているものであるが、その形
態は特に限定されるものではない。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. Further, as the bisphenol type epoxy resin, bisphenol A type, bisphenol AD
Type, bisphenol S type, bisphenol F type and the like can be used. Further, a styrene monomer, an acrylic monomer, etc. are usually blended in the vinyl ester resin as a cross-linking agent, but the form is not particularly limited.
【0023】アクリル樹脂としては、通常熱硬化型とし
て、メチルメタアクリレートモノマー、あるいは多官能
のアクリルモノマー、あるいはプレポリマー、あるいは
ポリマーのそれぞれ2種類以上の混合物で構成されたア
クリルシロップと称されるものを用いるが、その形態は
特に限定されるものではない。As the acrylic resin, what is called a thermosetting type acrylic syrup which is usually composed of a methylmethacrylate monomer, a polyfunctional acrylic monomer, a prepolymer, or a mixture of two or more kinds of polymers, respectively. However, the form is not particularly limited.
【0024】また、ポリエステル樹脂、ビニルエステル
樹脂、アクリル樹脂の2種類以上の混合系とする場合
は、樹脂それぞれの特性及び充填剤との相互作用あるい
は添加配合物との相互作用などにより目的とする製品品
質に合った最適配合が求められるが、その配合量は特に
限定されるものではない。When a mixture of two or more kinds of polyester resin, vinyl ester resin and acrylic resin is used, the purpose is to be determined by the characteristics of each resin and the interaction with the filler or the additive compound. The optimum blending that matches the product quality is required, but the blending amount is not particularly limited.
【0025】充填剤は、水酸化アルミニウム、シリカ、
ガラスパウダーのうちの1種類、あるいは2種類以上の
混合物として用いることができる。充填剤の配合量は、
熱硬化性樹脂100重量部に対して100〜300重量
部とすることが好ましく、この範囲に満たないと、製品
の耐衝撃強度は優れるが耐熱性を十分に発揮できないお
それがあり、また、この範囲を越えると耐熱性は優れる
が耐衝撃強度が低下するおそれがある。The filler is aluminum hydroxide, silica,
It can be used as one kind of glass powder or a mixture of two or more kinds. The blending amount of the filler is
The amount is preferably 100 to 300 parts by weight with respect to 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 may not be sufficiently exhibited. If it exceeds the range, the heat resistance is excellent, but the impact strength may decrease.
【0026】充填剤の粒径は小さいほど人造大理石製品
の耐衝撃強度を向上させることができるが、樹脂組成物
の粘度を急激に上昇させて製造が困難となるため、平均
粒径の下限を5μmとするのが好ましい。The smaller the particle size of the filler is, the more the impact resistance of the artificial marble product can be improved, but the viscosity of the resin composition sharply increases and the manufacturing becomes difficult. Therefore, the lower limit of the average particle size is set. It is preferably 5 μm.
【0027】一方、充填剤の粒径が大きくなると、樹脂
組成物1の粘度は低下して製造での問題は無くなるが、
人造大理石製品の耐衝撃強度が低下してしまう傾向にな
る。したがって平均粒径の上限を50μmとするのが好
ましい。On the other hand, when the particle size of the filler is large, the viscosity of the resin composition 1 is low and the problem in production is eliminated.
The impact resistance of the artificial marble product tends to decrease. Therefore, the upper limit of the average particle size is preferably 50 μm.
【0028】また充填剤は表面にシランカップリング処
理したものを用いると、その充填剤と樹脂との密着性を
向上でき、人造大理石製品の耐衝撃強度を向上させるこ
とができるものである。When the surface of the filler is silane-coupling treated, the adhesion between the filler and the resin can be improved and the impact resistance of the artificial marble product can be improved.
【0029】重合性溶剤は通常、熱硬化性樹脂の架橋剤
として用いられ、上記にあるようにスチレンモノマー
(SM)やアクリルモノマー(MMA)などである。な
るべく、注型用樹脂組成物に含有される重合性溶剤を用
いる方が物性の安定性の面からよいが、特にこれに限定
されるものではない。The polymerizable solvent is usually used as a cross-linking agent for the thermosetting resin, and as described above, it is a styrene monomer (SM) or an acrylic monomer (MMA). It is preferable to use the polymerizable solvent contained in the casting resin composition from the viewpoint of stability of physical properties, but the invention is not particularly limited thereto.
【0030】重合性溶剤としては、その他にパラメチル
スチレン(ビニルトルエン)やモノクロルスチレン、t
−ブチルスチレン、フェノキシエチル(メタ)アクリレ
ート、1,6−ヘキサンジオール(メタ)アクリレー
ト、トリメチロールプロパントリ(メタ)アクリレー
ト、2−ヒドロキシエチル(メタ)アクリレート、ジシ
クロペンテニルオキシエチルメタアクリレートなどがあ
る。Other polymerizable solvents include paramethylstyrene (vinyltoluene), monochlorostyrene, and t.
-Butylstyrene, phenoxyethyl (meth) acrylate, 1,6-hexanediol (meth) acrylate, trimethylolpropane tri (meth) acrylate, 2-hydroxyethyl (meth) acrylate, dicyclopentenyloxyethyl methacrylate, etc. .
【0031】更に、人造大理石成形用樹脂組成物には硬
化剤を配合する。Further, a curing agent is added to the artificial marble molding resin composition.
【0032】硬化剤としては、1,1,3,3−テトラ
メチルブチルパーオキシ−2−エチルヘキサノエートや
t−ヘキシルパーオキシ−2−エチルヘキサノエート等
を用いることができる。この硬化剤の配合割合は例えば
ビニルエステル樹脂の場合は、樹脂と架橋剤との総量1
00重量部に対して0.5〜5重量部とするのが好まし
いものである。As the curing agent, 1,1,3,3-tetramethylbutylperoxy-2-ethylhexanoate or t-hexylperoxy-2-ethylhexanoate can be used. For example, in the case of a vinyl ester resin, the mixing ratio of this curing agent is 1 total amount of the resin and the crosslinking agent.
It is preferably 0.5 to 5 parts by weight with respect to 00 parts by weight.
【0033】また、人造大理石成形用樹脂組成物には紫
外線吸収剤、減粘剤、離型剤、ガラス繊維、着色剤を配
合することもできる。Further, the artificial marble molding resin composition may be blended with an ultraviolet absorber, a viscosity reducer, a release agent, glass fibers and a colorant.
【0034】人造大理石成形用樹脂組成物は、大粒柄材
を含むこれらの配合物を所定の割合で配合し、撹拌機等
により撹拌して配合調製する。The artificial marble molding resin composition is prepared by mixing these compounds containing a large grain pattern material at a predetermined ratio and stirring them with a stirrer or the like.
【0035】人造大理石成形用樹脂組成物から人造大理
石を製造するに当たっては、その配合調製された人造大
理石成形用樹脂組成物を20〜50Torr程度の減圧
下で真空脱泡処理する。このようにして脱泡処理された
人造大理石成形用樹脂組成物を減圧状態から解放し、所
定形状の注型金型に注入して、この注型金型を50〜1
10℃の温度で30〜120分間加熱して人造大理石成
形用樹脂組成物の上記熱硬化性樹脂中の反応性不飽和基
と、同じく樹脂中の重合性モノマーとの共重合反応を進
行させて人造大理石成形用樹脂組成物の硬化成形を行う
ものである。In producing artificial marble from the artificial marble molding resin composition, the blended and prepared artificial marble molding resin composition is subjected to vacuum defoaming treatment under a reduced pressure of about 20 to 50 Torr. The artificial marble molding resin composition that has been degassed in this way is released from the depressurized state and poured into a casting mold of a predetermined shape, and the casting mold is made to have a volume of 50 to 1
The mixture is heated at a temperature of 10 ° C. for 30 to 120 minutes to promote a copolymerization reaction between the reactive unsaturated group in the thermosetting resin of the resin composition for artificial marble molding and the polymerizable monomer in the resin. The resin composition for artificial marble molding is cured and molded.
【0036】上記のようにして得た大粒柄材入り人造大
理石の成形品は、大粒柄材が均一に分散したもので、そ
の内部に大粒柄材同士がくっついたままの影響によるク
ラック形成や、それによる強度の低下もないもので、高
意匠のグラニット柄を持つ人造大理石の成形品が得られ
るものである。The molded article of artificial marble containing a large grain pattern material obtained as described above is one in which the large grain pattern materials are uniformly dispersed, and crack formation due to the influence of the large grain pattern materials remaining stuck to each other, There is no reduction in strength due to this, and an artificial marble molded product having a highly designed granite pattern can be obtained.
【0037】このような人造大理石の成形品は、洗面カ
ウンター、キッチンカウンター、浴槽、洗面ボールなど
への商品化が容易となるものである。Such an artificial marble molded article can be easily commercialized as a wash counter, a kitchen counter, a bathtub, a wash bowl, or the like.
【0038】[0038]
【実施例】以下、本発明を実施例により詳述する。
(実施例1)熱硬化性樹脂として、ポリエステル樹脂
(武田薬品(株)製 ポリマール5450)を用い、こ
の樹脂100重量部に対し、充填剤として水酸化アルミ
ニウム(昭和電工(株)製 H−310 平均粒径17
μm)を130重量部配合し、これに着色剤として黒の
トナーを0.5重量部添加し、更に、硬化剤(日本油脂
(株)製 パーキュアHO)を3.0重量部添加して柄
材用樹脂組成物となるコンパウンドを得た。これを20
Torrの減圧下で60分間真空脱泡処理しながら撹拌
混合した後、柄材成形用金型内に注入して金型温度を1
00℃で120分間加熱して硬化させ、クラッシャーで
粉砕して分級し、黒色の平均厚み0.5mm、平均粒径
3.5mmの大粒柄材を得た。得られた大粒柄材をスチ
レンモノマー溶液中に撹拌しながら混ぜ込み、混ぜ込み
終了後、この大粒柄材を金網上にすくい上げて過剰のス
チレンモノマーを取り除いた。一方で、上記と同様で着
色剤の添加のないコンパウンドを別に用意し、このコン
パウンドに上記の大粒柄材を5.0重量部添加して人造
大理石成形用樹脂組成物を得た。これを20Torrの
減圧下で60分間真空脱泡処理しながら撹拌混合した
後、所定形状で12mm厚に設定された注型金型内に注
入して金型温度を100℃で120分間加熱して硬化さ
せ、黒色の大粒柄材の入ったグラニット調の人造大理石
を得た。
(実施例2)熱硬化性樹脂として、ビニルエステル樹脂
(武田薬品(株)製 プロミネートP−311)を用
い、この樹脂100重量部に対し、充填剤として水酸化
アルミニウム(昭和電工(株)製 H−308B 平均
粒径8μm)を150重量部配合し、これに着色剤とし
て黒のトナーを0.3重量部添加し、更に、硬化剤(日
本油脂(株)製 パーキュアHO)を2.0重量部添加
して柄材用樹脂組成物となるコンパウンドを得た。これ
を20Torrの減圧下で60分間真空脱泡処理しなが
ら撹拌混合した後、柄材成形用金型内に注入して金型温
度を100℃で120分間加熱して硬化させ、クラッシ
ャーで粉砕して分級し、黒色の平均厚み0.6mm、平
均粒径4.5mmの大粒柄材を得た。得られた大粒柄材
をビニルトルエン溶液中に撹拌しながら混ぜ込み、混ぜ
込み終了後、この大粒柄材を金網上にすくい上げて過剰
のビニルトルエンを取り除いた。一方で、上記と同様で
着色剤の添加のないコンパウンドを別に用意し、このコ
ンパウンドに上記の大粒柄材を5.5重量部添加して人
造大理石成形用樹脂組成物を得た。これを20Torr
の減圧下で60分間真空脱泡処理しながら撹拌混合した
後、所定形状で11mm厚に設定された注型金型内に注
入して金型温度を100℃で110分間加熱して硬化さ
せ、黒色の大粒柄材の入ったグラニット調の人造大理石
を得た。
(実施例3)熱硬化性樹脂として、アクリルシロップ樹
脂(日本フェロー(株)製 AC−02)を用い、この
樹脂100重量部に対し、充填剤としてシリカ(龍森
(株)製 CRYSTALITE M−3K 平均粒径
20μm)を130重量部配合し、これに着色剤として
グレー色のトナーを0.6重量部添加し、更に、硬化剤
(化薬アクゾ(株)製 パーカドックス16)を1.6
重量部添加して柄材用樹脂組成物となるコンパウンドを
得た。これを20Torrの減圧下で60分間真空脱泡
処理しながら撹拌混合した後、柄材成形用金型内に注入
して金型温度を100℃で120分間加熱して硬化さ
せ、クラッシャーで粉砕して分級し、グレー色の平均厚
み1.0mm、平均粒径4.0mmの大粒柄材を得た。
得られた大粒柄材をメチルメタアクリレート(MMA)
溶液中に撹拌しながら混ぜ込み、混ぜ込み終了後、この
大粒柄材を金網上にすくい上げて過剰のメチルメタアク
リレート(MMA)を取り除いた。一方で、上記と同様
で着色剤の添加のないコンパウンドを別に用意し、この
コンパウンドに上記の大粒柄材を6.5重量部添加して
人造大理石成形用樹脂組成物を得た。これを20Tor
rの減圧下で60分間真空脱泡処理しながら撹拌混合し
た後、所定形状で15mm厚に設定された注型金型内に
注入して金型温度を90℃で120分間加熱して硬化さ
せ、グレー色の大粒柄材の入ったグラニット調の人造大
理石を得た。
(実施例4)熱硬化性樹脂として、ビニルエステル樹脂
(昭和高分子(株)製 リポキシR−804)と、ポリ
エステル樹脂(武田薬品(株)製 ポリマール525
0)を60/40の配合比で混合し、この混合樹脂10
0重量部に対し、充填剤として水酸化アルミニウム(昭
和電工(株)製 H−320 平均粒径10μm)を1
50重量部配合し、これに着色剤としてブラウン色のト
ナーを0.6重量部添加し、更に、硬化剤(日本油脂
(株)製 パーキュアHO)を3.0重量部添加して柄
材用樹脂組成物となるコンパウンドを得た。これを20
Torrの減圧下で60分間真空脱泡処理しながら撹拌
混合した後、柄材成形用金型内に注入して金型温度を9
0℃で120分間加熱して硬化させ、クラッシャーで粉
砕して分級し、ブラウン色の平均厚み1.5mm、平均
粒径4.0mmの大粒柄材を得た。得られた大粒柄材を
熱硬化性樹脂溶液中に撹拌しながら混ぜ込み、混ぜ込み
終了後、この大粒柄材を金網上にすくい上げて過剰の熱
硬化性樹脂溶液を取り除いた。一方で、上記と同様で着
色剤の添加のないコンパウンドを別に用意し、このコン
パウンドに上記の大粒柄材を6.5重量部添加して人造
大理石成形用樹脂組成物を得た。これを20Torrの
減圧下で60分間真空脱泡処理しながら撹拌混合した
後、所定形状で12mm厚に設定された注型金型内に注
入して金型温度を90℃で120分間加熱して硬化さ
せ、ブラウン色の大粒柄材の入ったグラニット調の人造
大理石を得た。
(実施例5)熱硬化性樹脂として、ビニルエステル樹脂
(昭和高分子(株)製 リポキシR−804)と、アク
リルシロップ樹脂(三井化学(株)製 XE924−
1)を75/25の配合比で混合し、この混合樹脂10
0重量部に対し、充填剤として水酸化アルミニウム(昭
和電工(株)製 H−320 平均粒径10μm)とガ
ラスパウダー(日本フリット(株)製 GF−2−30
A 平均粒径30μm)を80/20で混合したものを
160重量部配合し、これに着色剤としてブラウン色の
トナーを0.5重量部添加し、更に、硬化剤(日本油脂
(株)製 パーキュアWO)を3.0重量部添加して柄
材用樹脂組成物となるコンパウンドを得た。これを20
Torrの減圧下で60分間真空脱泡処理しながら撹拌
混合した後、柄材成形用金型内に注入して金型温度を9
0℃で120分間加熱して硬化させ、クラッシャーで粉
砕して分級し、ブラウン色の平均厚み0.8mm、平均
粒径5.0mmの大粒柄材を得た。得られた大粒柄材を
熱硬化性樹脂溶液中に撹拌しながら混ぜ込み、混ぜ込み
終了後、この大粒柄材を金網上にすくい上げて過剰の熱
硬化性樹脂溶液を取り除いた。一方で、上記と同様で着
色剤の添加のないコンパウンドを別に用意し、このコン
パウンドに上記の大粒柄材を10.0重量部添加して人
造大理石成形用樹脂組成物を得た。これを20Torr
の減圧下で60分間真空脱泡処理しながら撹拌混合した
後、所定形状で10mm厚に設定された注型金型内に注
入して金型温度を90℃で120分間加熱して硬化さ
せ、ブラウン色の大粒柄材の入ったグラニット調の人造
大理石を得た。EXAMPLES The present invention will be described in detail below with reference to examples. (Example 1) A polyester resin (Polymer 5450 manufactured by Takeda Pharmaceutical Co., Ltd.) was used as a thermosetting resin, and 100 parts by weight of this resin was used as a filler of aluminum hydroxide (H-310 manufactured by Showa Denko KK). Average particle size 17
μm) in an amount of 130 parts by weight, to which 0.5 part by weight of black toner as a colorant was added, and further 3.0 parts by weight of a curing agent (Percure HO manufactured by NOF CORPORATION) was added. The compound used as the resin composition for materials was obtained. 20 this
After stirring and mixing under vacuum defoaming treatment under reduced pressure of Torr for 60 minutes, the mixture is poured into a mold for pattern material molding and the mold temperature is set to 1
The mixture was heated at 00 ° C. for 120 minutes for curing, crushed with a crusher and classified to obtain a black large-sized handle material having an average thickness of 0.5 mm and an average particle diameter of 3.5 mm. The obtained large grain pattern material was mixed into a styrene monomer solution while stirring, and after the mixing was completed, the large grain pattern material was scooped up on a wire net to remove excess styrene monomer. On the other hand, a compound similar to the above, but without addition of a coloring agent was prepared separately, and 5.0 parts by weight of the above-mentioned large grain pattern material was added to this compound to obtain a resin composition for artificial marble molding. After stirring and mixing this under vacuum degassing treatment for 20 minutes under a reduced pressure of 20 Torr, it is poured into a casting mold having a predetermined shape and a thickness of 12 mm, and the mold temperature is heated at 100 ° C. for 120 minutes. It was cured to obtain a granite-like artificial marble containing a large black pattern material. (Example 2) A vinyl ester resin (Prominate P-311 manufactured by Takeda Pharmaceutical Co., Ltd.) was used as a thermosetting resin, and 100 parts by weight of this resin was used as a filler of aluminum hydroxide (manufactured by Showa Denko KK). H-308B (average particle size: 8 μm) was mixed in an amount of 150 parts by weight, 0.3 part by weight of black toner was added as a colorant, and a curing agent (Percure HO manufactured by NOF CORPORATION) was added to 2.0 parts. A compound to be a resin composition for pattern material was obtained by adding parts by weight. After stirring and mixing this under vacuum defoaming treatment for 20 minutes under a reduced pressure of 20 Torr, it is poured into a mold for pattern material molding, heated at a mold temperature of 100 ° C. for 120 minutes to cure, and crushed with a crusher. And classified to obtain a large-sized black pattern material having an average thickness of 0.6 mm and an average particle diameter of 4.5 mm. The obtained large grain pattern material was mixed into a vinyltoluene solution while stirring, and after the mixing was completed, the large grain pattern material was scooped up on a wire net to remove excess vinyltoluene. On the other hand, a compound similar to the above, but without the addition of a coloring agent was prepared separately, and 5.5 parts by weight of the above-mentioned large grain pattern material was added to this compound to obtain a resin composition for artificial marble molding. 20 Torr
After stirring and mixing under reduced pressure for 60 minutes under vacuum degassing treatment, the mixture is poured into a casting mold having a predetermined shape and a thickness of 11 mm, and the mold temperature is heated at 100 ° C. for 110 minutes to be cured, A granite-like artificial marble containing a large black pattern material was obtained. (Example 3) Acrylic syrup resin (AC-02 manufactured by Nippon Fellow Co., Ltd.) was used as a thermosetting resin, and 100 parts by weight of this resin was used as a filler for silica (CRYSTALITE M- manufactured by Tatsumori Co., Ltd.). 130 parts by weight of 3K average particle size 20 μm) was added, 0.6 parts by weight of a gray toner as a colorant was added thereto, and a curing agent (Perkadox 16 manufactured by Kayaku Akzo Co., Ltd.) was added. 6
A compound to be a resin composition for pattern material was obtained by adding parts by weight. After stirring and mixing this under vacuum defoaming treatment for 20 minutes under a reduced pressure of 20 Torr, it is poured into a mold for pattern material molding, heated at a mold temperature of 100 ° C. for 120 minutes to cure, and crushed with a crusher. And classified to obtain a large grain pattern material having a gray color and an average thickness of 1.0 mm and an average particle diameter of 4.0 mm.
The obtained large grain pattern material is methyl methacrylate (MMA)
This was mixed into the solution with stirring, and after the completion of the mixing, this large grain handle was scooped up on a metal net to remove excess methyl methacrylate (MMA). On the other hand, a compound similar to the above, but without addition of a coloring agent was prepared separately, and 6.5 parts by weight of the above-mentioned large grain handle material was added to this compound to obtain a resin composition for artificial marble molding. This is 20 Tor
After stirring and mixing under vacuum defoaming treatment for 60 minutes under a reduced pressure of r, the mixture is poured into a casting mold having a predetermined shape and a thickness of 15 mm and heated at 90 ° C. for 120 minutes to cure. A granite-like artificial marble containing a large-sized gray colored pattern material was obtained. (Example 4) As a thermosetting resin, vinyl ester resin (Lipoxy R-804 manufactured by Showa Highpolymer Co., Ltd.) and polyester resin (Polymer 525 manufactured by Takeda Pharmaceutical Co., Ltd.)
0) is mixed at a compounding ratio of 60/40, and the mixed resin 10
Aluminum hydroxide (H-320 manufactured by Showa Denko KK, average particle size 10 μm) was added to 1 part by weight of 0 parts by weight.
50 parts by weight were added, and 0.6 part by weight of a brown toner was added as a colorant to the mixture, and further 3.0 parts by weight of a curing agent (Percure HO manufactured by NOF CORPORATION) was added to the pattern material. A compound to be a resin composition was obtained. 20 this
After stirring and mixing under vacuum defoaming treatment for 60 minutes under a reduced pressure of Torr, the mixture is poured into a pattern material molding die and the mold temperature is set to 9
The mixture was heated at 0 ° C. for 120 minutes to be hardened, crushed with a crusher and classified to obtain a large grain pattern material of brown color having an average thickness of 1.5 mm and an average particle diameter of 4.0 mm. The obtained large grain pattern material was mixed into the thermosetting resin solution while stirring, and after the mixing was completed, the large grain pattern material was scooped up on the wire netting to remove the excess thermosetting resin solution. On the other hand, a compound similar to the above, but without addition of a coloring agent was prepared separately, and 6.5 parts by weight of the above-mentioned large grain handle material was added to this compound to obtain a resin composition for artificial marble molding. After stirring and mixing this under vacuum degassing treatment for 60 minutes under a reduced pressure of 20 Torr, it was poured into a casting mold having a predetermined shape and a thickness of 12 mm, and the mold temperature was heated at 90 ° C. for 120 minutes. After curing, a granite-like artificial marble containing large brown-colored pattern material was obtained. (Example 5) As thermosetting resins, vinyl ester resin (Lipoxy R-804 manufactured by Showa Highpolymer Co., Ltd.) and acrylic syrup resin (XE924-Mitsui Chemicals Co., Ltd.)
1) was mixed at a compounding ratio of 75/25, and the mixed resin 10
Aluminum hydroxide (Showa Denko KK H-320 average particle size 10 μm) and glass powder (Nippon Frit GF-2-30) are used as fillers based on 0 parts by weight.
A average particle size of 30 μm) was mixed at a ratio of 80/20 to 160 parts by weight, to which 0.5 part by weight of a brown toner was added as a colorant, and a curing agent (manufactured by NOF CORPORATION). 3.0 parts by weight of Percure WO) was added to obtain a compound to be a resin composition for a pattern material. 20 this
After stirring and mixing under vacuum defoaming treatment for 60 minutes under a reduced pressure of Torr, the mixture is poured into a pattern material molding die and the mold temperature is set to 9
The mixture was heated at 0 ° C. for 120 minutes to be cured, crushed with a crusher and classified to obtain a large grain pattern material of brown color having an average thickness of 0.8 mm and an average particle diameter of 5.0 mm. The obtained large grain pattern material was mixed into the thermosetting resin solution while stirring, and after the mixing was completed, the large grain pattern material was scooped up on the wire netting to remove the excess thermosetting resin solution. On the other hand, a compound similar to the above, but without addition of a coloring agent was prepared separately, and 10.0 parts by weight of the above-mentioned large grain handle material was added to this compound to obtain a resin composition for artificial marble molding. 20 Torr
After stirring and mixing under vacuum degassing for 60 minutes under reduced pressure, the mixture is poured into a casting mold having a predetermined shape and a thickness of 10 mm, and the mold temperature is heated at 90 ° C. for 120 minutes to be cured, A granite-like artificial marble containing large brown-colored pattern material was obtained.
【0039】[0039]
【発明の効果】上記のように本発明にあっては、熱硬化
性樹脂に充填剤、内部離型剤、硬化剤などの添加物を配
合したコンパウンドに柄材を添加して人造大理石成形用
樹脂組成物を得て、この人造大理石成形用樹脂組成物を
成形硬化させて人造大理石を得る人造大理石の製造方法
において、大粒柄材をあらかじめ重合性の溶剤あるいは
熱硬化性樹脂で混ぜ合わせた後、コンパウンドと混練し
て大粒柄材入り人造大理石成形用樹脂組成物としたの
で、人造大理石成形用樹脂組成物に大粒柄材を添加配合
しても柄材同士がくっつくことがなくて均一に分散混練
配合できこの結果、大粒柄材同士がくっついたまま成形
されることがなくて大粒柄材同士の間にコンパウンド成
分が介在しないというようなことがなく、内部にクラッ
クが入っ形とならず、これらの結果、大粒の柄材を添加
して均一に分散し製品強度の低下を招かない高級感のあ
る高意匠柄あるいはグラニット柄の人造大理石を製造す
ることができるものである。As described above, according to the present invention, a pattern material is added to a compound in which a thermosetting resin is mixed with an additive such as a filler, an internal mold release agent, and a curing agent for artificial marble molding. Obtaining a resin composition and molding and curing this resin composition for artificial marble to obtain an artificial marble. In a method for producing an artificial marble, after mixing a large grain pattern material with a polymerizable solvent or a thermosetting resin in advance. Since it is kneaded with the compound to make a resin composition for artificial marble molding containing a large grain pattern material, even if a large pattern material is added to the resin composition for artificial marble molding, the pattern materials do not stick to each other and are dispersed uniformly. As a result of kneading and mixing, as a result, there is no possibility that large grain pattern materials will not be molded while sticking to each other and there will be no compound component between the large grain pattern materials, and cracks will not form inside These results, in which it is possible to produce the artificial marble high design pattern or granite pattern feeling of luxury does not cause a decrease in product strength uniformly dispersed by adding a handle member having a large particle.
───────────────────────────────────────────────────── フロントページの続き Fターム(参考) 4F204 AA36 AA41 AA43 AB03 AB07 AB11 AC01 AF09 AH44 EA03 EA04 EB01 EE22 EF01 EF02 ─────────────────────────────────────────────────── ─── Continued front page F term (reference) 4F204 AA36 AA41 AA43 AB03 AB07 AB11 AC01 AF09 AH44 EA03 EA04 EB01 EE22 EF01 EF02
Claims (4)
化剤などの添加物を配合したコンパウンドに柄材を添加
して人造大理石成形用樹脂組成物を得て、この人造大理
石成形用樹脂組成物を成形硬化させて人造大理石を得る
人造大理石の製造方法において、大粒柄材をあらかじめ
重合性の溶剤で混ぜ合わせた後、コンパウンドと混練し
て大粒柄材入り人造大理石成形用樹脂組成物としたこと
を特徴とする人造大理石の製造方法。1. An artificial marble molding resin composition is obtained by adding a pattern material to a compound in which a thermosetting resin is mixed with an additive such as a filler, an internal mold release agent, and a curing agent. In the method for producing an artificial marble by molding and curing the resin composition for use in manufacturing an artificial marble, the resin composition for artificial marble molding containing a large grain pattern material after mixing the large grain pattern material in advance with a polymerizable solvent and kneading with the compound. A method for producing an artificial marble, which is characterized by being a product.
化剤などの添加物を配合したコンパウンドに柄材を添加
して人造大理石成形用樹脂組成物を得て、この人造大理
石成形用樹脂組成物を成形硬化させて人造大理石を得る
人造大理石の製造方法において、大粒柄材をあらかじめ
熱硬化性樹脂で混ぜ合わせた後、コンパウンドと混練し
て大粒柄材入り人造大理石成形用樹脂組成物としたこと
を特徴とする人造大理石の製造方法。2. A resin composition for artificial marble molding is obtained by adding a pattern material to a compound in which a thermosetting resin is mixed with an additive such as a filler, an internal release agent, and a curing agent, and the artificial marble molding is obtained. In a method for producing an artificial marble by molding and curing a resin composition for use in manufacturing an artificial marble, a resin composition for forming an artificial marble containing a large pattern material, which is obtained by previously mixing a large grain pattern material with a thermosetting resin and then kneading with a compound. A method for producing an artificial marble, which is characterized by being a product.
ルエステル樹脂、アクリル樹脂の内の1種類、あるいは
2種類以上の混合物であることを特徴とする請求項1又
は請求項2記載の人造大理石の製造方法。3. The artificial marble according to claim 1, wherein the thermosetting resin is one kind of a polyester resin, a vinyl ester resin and an acrylic resin, or a mixture of two or more kinds. Production method.
mで且つ平均粒径1mm以上であることを特徴とする請
求項1又は請求項2記載の人造大理石の製造方法。4. The average thickness of the large grain pattern material is 0.1 to 3.0 m.
The method for producing an artificial marble according to claim 1 or 2, wherein m and the average particle size are 1 mm or more.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
JP2001329897A JP2003127150A (en) | 2001-10-26 | 2001-10-26 | Method for producing artificial marble |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
JP2001329897A JP2003127150A (en) | 2001-10-26 | 2001-10-26 | Method for producing artificial marble |
Publications (1)
Publication Number | Publication Date |
---|---|
JP2003127150A true JP2003127150A (en) | 2003-05-08 |
Family
ID=19145713
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
JP2001329897A Withdrawn JP2003127150A (en) | 2001-10-26 | 2001-10-26 | Method for producing artificial marble |
Country Status (1)
Country | Link |
---|---|
JP (1) | JP2003127150A (en) |
-
2001
- 2001-10-26 JP JP2001329897A patent/JP2003127150A/en not_active Withdrawn
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