JP2005298270A - Method of manufacturing artificial marble having patterns - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method of manufacturing an artificial marble in which patterns being soft and having no directional properties, or suppressed in directional property can be formed easily, and also, the control of such patters is easy. <P>SOLUTION: The method of manufacturing the artificial marble having patterns includes processes for forming a layer(I) 3 by injecting a liquid resin (A) into a forming cell; injecting a liquid resin (B) having a color different from that of the liquid resin (A) in striped state to form a stripe layer(II) 2 on the layer(I) 3, mixing the layer(I) 3 and the layer(II) 2 with a comb-shaped member 1 to form patterns, and then hardening the liquid resin (A) and the liquid resin (B). <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a method for producing artificial marble having a pattern that is soft and has no directionality or has a suppressed directionality. More specifically, the present invention relates to a method for producing artificial marble that can easily form such a pattern and that can be easily controlled.

Conventionally, an artificial marble used for a counter of a washstand, a table top or the like has been manufactured by curing a liquid resin. In Patent Document 1, the inventors of the present invention manufactured an artificial marble having a stripe pattern by laminating liquid resins of different colors in layers in a molding cell, and curing the comb-shaped tool after moving it in the molding cell. Proposed method to do. Further, in Patent Document 2, Patent Document 3 and Patent Document 4, a liquid resin in which a colorant is unevenly dispersed is injected into the lowermost layer of the molding cell, and the comb-like tool with blur forming means is moved in the molding cell. Proposed a method for producing artificial marble with a grain pattern or stripe pattern with natural marble appearance. Furthermore, in patent document 5, the manufacturing apparatus for implementing continuously the manufacture of the artificial marble with a stripe pattern on an industrial scale was proposed. Patent Document 6 discloses a method for producing artificial marble having a wave or wood grain pattern by supplying a liquid resin having different hues and viscosities to a moving belt by partially mixing the resin with a rotating body provided inside the resin. Has been.
Japanese Patent Laid-Open No. 10-128771 JP-A-10-323848 JP-A-11-277552 JP 11-291267 A JP-A-11-291268 JP 2001-170949 A

  According to each conventional method described above, it is possible to form a directional pattern such as a stripe pattern, a wave pattern, or a grain pattern. However, it is not possible to easily form a pattern with no directionality or with reduced directionality.

  An object of the present invention is to provide a method for producing an artificial marble which can easily form a pattern which is soft and has no directionality or which has a suppressed directionality, and which can be easily controlled.

  In the present invention, a liquid resin (A) is injected into a molding cell to form a layer (I), and then a liquid resin (B) having a color different from that of the liquid resin (A) is formed on the layer (I). ) In the form of stripes to form a layer (II) of stripes, and a pattern is formed by mixing layers (I) and (II) with a comb-like member, and then liquid resin (A) and liquid resin It is a manufacturing method of the artificial marble which has a pattern including the process of hardening (B).

  In the present invention, the liquid resin (A) mixed with the pigment (a) is injected into the molding cell to form the layer (I), and then the pigment (b) is formed on the layer (I). The liquid resin (B) mixed with is injected into the stripe shape to form the stripe layer (II), and the pattern is formed by mixing the layers (I) and (II) with a comb-like member, It is a manufacturing method of the artificial marble which has a pattern including the process of hardening liquid resin (A) and liquid resin (B).

  According to the present invention, it is possible to easily form a pattern that is soft and has no directionality or has reduced directionality. Further, the pattern can be easily controlled by appropriately changing the tooth shape, the tooth moving direction, the moving speed, and the like of the comb-like member.

  In the method of the present invention, first, a liquid resin as a raw material for artificial marble is injected into a molding cell. Specifically, the liquid resin (A) is first injected to form the layer (I), and then the liquid resin (B) having a different color from the liquid resin (A) is striped on the layer (I). The stripe layer (II) is formed.

  As a method for changing the color of the liquid resin (B) to a color different from the color of the liquid resin (A), a method of mixing a pigment with either the liquid resin (A) or (B), a liquid resin (A ) And (B) are mixed with different amounts of the same pigment, and liquid resins (A) and (B) are mixed with different pigments. Further, pulverized resin particles containing a pigment can be contained instead of the pigment.

  A method in which different pigments are mixed in the liquid resins (A) and (B) is preferable from the viewpoint that the types of patterns to be formed can be increased, or the delicate texture and contrast of the patterns can be adjusted. Hereinafter, a method of mixing different pigments in the liquid resins (A) and (B) will be described in detail.

  First, the liquid resin (A) mixed with the pigment (a) is injected to form the layer (I), and then the liquid resin (B) mixed with the pigment (b) is formed on the layer (I). The stripe layer (II) is formed by injecting in stripes.

  For example, using a bifurcated distributor, the liquid resin is divided into two liquids, one liquid resin is mixed with the pigment (a) and colored, and the other liquid resin is mixed with a different color pigment (b). The method of preparing liquid resin (A) and liquid resin (B) by coloring is simple. Then, this liquid resin (A) is injected into the molding cell to form a lower layer (I), and then the liquid resin (B) is injected into the stripe shape to form a stripe layer (II). do it.

  The mixed state of the pigment (a) and the pigment (b) in the liquid resin may be uniform or non-uniform. The subtle texture of the finally obtained artificial marble pattern can be changed by this uniform or non-uniform mixed state.

  The width and interval of the stripe pattern in the layer (II) are not particularly limited. However, for example, in the width direction of the forming cell (perpendicular to the relative movement direction of the forming cell and the distributor), the width and interval of the stripes are constant and about 10 to 150 mm, respectively. Preferred for controlling expression.

  The thickness of each of the layers (I) and (II) is preferably about 2 to 20 mm.

  Liquid resin (A) and liquid resin (B) should just be resin containing a pigment, and the composition in particular is not restrict | limited. Preferable examples include a liquid resin composition comprising a mixture of a monomer such as a methacrylic ester and a polymer thereof, syrup, a filler, the pigment (a) or (b), and a curing catalyst.

  Examples of the pigments (a) and (b) include zinc oxide, white titanium oxide, zinc sulfide; yellow iron oxide yellow; black iron oxide black; red iron oxide red; blue ultramarine blue and phthalocyanine blue. Etc.

  Examples of the filler include inorganic fillers such as aluminum hydroxide, magnesium hydroxide, and calcium hydroxide. Examples of the curing catalyst include tertiary butyl peroxymaleic acid, benzoyl peroxide, cumene hydroperoxide, tertiary butyl hydroperoxide, lauroyl peroxide, azobisisobutyronitrile, and the like. In addition to these components, various components conventionally known as additive components for artificial marble, such as colored resin particles, dyes, UV absorbers, flame retardants, mold release agents, fluidizing agents, thickeners, polymerization prohibition Agents, antioxidants, etc. can be added.

  Of the physical properties of the liquid resins (A) and (B), it is the viscosity of the resin that has a particularly great influence on the formation of the pattern. The viscosity is preferably in the range of 0.3 to 5 Pa · s from the viewpoint of controlling the expression of a desired pattern.

  In the present invention, it is preferable to prepare a liquid resin (A) and a liquid resin (B) by dividing an appropriate liquid resin into two and mixing the pigment (a) and the pigment (b) respectively. In this case, since the components related to the curing of both liquid resins are contained in substantially the same amount, there is no adverse effect due to the difference in curing speed. As a result, the mechanical properties of the artificial marble do not deteriorate. Specifically, it is preferable to divide the liquid resin into two liquids using a bifurcated distributor, and mix and color the pigments of different colors, as in the examples described later.

  In the present invention, the pattern is formed on the upper surface of the layer (I) and the layer (II) laminated in the molding cell as described above by mixing with a comb-like member. The mixing by the comb-shaped member is an operation for forming a desired pattern. Here, when mixing by the comb-like member is started, the layers (liquid resins) begin to mix, and the stripe pattern formed by the layer (II) gradually starts to lose directionality. If the mixing is further continued, the two will eventually be completely uniformly mixed, and the pattern will disappear. In the present invention, in order to form a desired pattern, moderate mixing (incomplete mixing) is performed to such an extent that the layers (liquid resins) are not completely uniformly mixed. As a result, a desired pattern having no directionality or suppressed directionality is formed. Specifically, for example, the teeth of the comb-like member may be immersed in the layer (I) and the layer (II) and moved so as to be stirred. By appropriately changing the tooth shape, the tooth moving direction, the moving speed, and the like of the comb-like member, the pattern to be formed can be easily controlled.

  FIG. 1 is a schematic diagram showing an example of a state of mixing with a comb-like member in the present invention. In this figure, a striped layer (II) 2 is formed using the liquid resin (B) on the layer (I) 3 formed using the liquid resin (A). Here, the layer (I) serves as the base portion of the artificial marble, and the layer (II) serves as the pattern portion. By immersing the tips of the teeth of the comb-like member 1 in the liquid resin having such a stripe pattern, the layer (I) and the layer can be moved by moving in the direction across the stripe, rotating, or combining them. (II) can be mixed moderately and a desired pattern can be formed on the upper surface of the liquid resin.

  The comb-like member 2 is preferably made of a material that is inert to each liquid resin and does not exhibit adhesiveness. Specific examples include metals such as aluminum and organic materials coated with polytetrafluoroethylene.

  FIG. 2 is a schematic view showing an example of a comb-like member used in the present invention. A comb-like member 1 shown in FIG. 2 includes a plurality of strip-shaped teeth 4 arranged in a line in parallel at a desired interval, and a portion connecting one end of the plurality of teeth 4.

  The length of the teeth of the comb-like member is sufficiently longer than the total thickness of the stacked layers (I) and (II) so as not to cause unnecessary disturbance in the upper layer of the stripe (II). It is appropriate to be. The tooth width is preferably 5 to 20 mm. Since the tooth width and the tooth spacing affect the appearance of the pattern to be formed, an appropriate tooth width and tooth spacing may be selected according to the desired pattern. The thickness of the teeth may be a thickness that can maintain the mechanical strength, and does not significantly affect the formation of the pattern.

  In the present invention, the molding cell is not particularly limited. Conventionally, it is possible to use various molding cells that are known to be applicable to applications for molding and curing a liquid resin. In particular, as in the examples to be described later, a continuous manufacturing apparatus is used in which a belt made of stainless steel or the like is used as the bottom surface of the molding cell, and liquid resin is continuously supplied on the belt while the belt is moved, followed by curing by heating. Is preferred.

  The method of forming the stripe layer (II) by injecting the liquid resin (B) in a stripe shape on the layer (I) is not particularly limited. What is necessary is just to supply using the various supply liquid distribution means known conventionally. Specifically, it is preferable to arrange a distribution plate at the liquid resin supply port of the continuous production apparatus as in the embodiments described later.

  When the continuous production apparatus is used, the direction of the stripe of the liquid resin having the stripe pattern composed of the layer (I) and the layer (II) is usually parallel to the moving direction of the molding cell. Here, the comb-shaped member is preferably reciprocated in a direction crossing the stripe, that is, a direction different from the moving direction of the forming cell (preferably a vertical direction) and is simultaneously rotated. At that time, the moving speed of the comb-shaped member is important in relation to the moving speed of the forming cell. If the moving speed of the comb-like member is appropriately increased, the liquid resin can be sufficiently stirred, and a desired pattern can be easily obtained. However, if the moving speed is too high, the liquid resin may be excessively stirred, and the pattern may disappear, or bubbles may be generated in the liquid resin and the product yield may be reduced. In consideration of such points, the moving speed of the comb-shaped member may be appropriately set to an appropriate level so that a desired pattern can be formed. Specifically, the moving speed of the comb member is preferably about 20 to 40 cm / second.

  In this invention, after mixing with a comb-shaped member, liquid resin (A) and liquid resin (B) are hardened. As the curing method, various methods conventionally known as methods for curing a liquid resin can be used. An artificial marble can be obtained by removing the cured product from the molding cell. In this artificial marble, a desired pattern is formed on the surface opposite to the contact surface with the bottom surface of the molding cell (that is, the upper surface on the layer (II) side). This pattern is formed by appropriately imperfectly mixing the liquid resin (A) and the liquid resin (B) in which different color pigments (a) and (b) are mixed uniformly or non-uniformly. There is no directionality or the directionality is suppressed.

  Hereinafter, the present invention will be described in more detail with reference to examples. “%” And “part” in the examples mean “% by mass” and “part by mass”, respectively.

<Example 1>
1000 parts of methyl methacrylate syrup (hereinafter abbreviated as “syrup”) consisting of a mixture of 20% polymethyl methacrylate and 80% methyl methacrylate, aluminum hydroxide powder (trade name BS-33, manufactured by Nippon Light Metal Co., Ltd.) ) 1630 parts, ethylene glycol dimethacrylate 12 parts, tertiary butyl peroxymaleic acid 20 parts, and 2 parts deionized water were mixed and stirred with a mixer to obtain a mixed slurry. This mixed slurry was degassed in a vacuum vessel, and 0.1 part of glycol dimercaptoacetate and 8 parts of a slurry in which 25% of calcium hydroxide was dispersed in syrup were added and stirred to prepare a base mix. The viscosity of the base mix was 1 Pa · s.

  This base mix was led to the liquid resin supply means (distributor) 6 of the artificial marble continuous production apparatus shown in FIG. The front end of the liquid resin supply means 6 is branched into two, and the base mix is distributed here. Furthermore, the coloring agent supply piping 17 is connected to each of the two branched pipes, and here, for each 100 parts of the base mix, coloring agent compositions No. 1 and No. 1 having the composition described in Table 1 below. 2 were each fed. Colorant composition No. 1 is obtained by blending paste-like zinc oxide as pigment (a) in the same syrup used in the preparation of the base mix. Colorant composition No. 2 is a mixture of paste-like titanium oxide as pigment (b) in the syrup. Further, the two branched pipes are each provided with a non-stirring mixer (static mixer) 11 where the base mix containing the colorant composition is mixed uniformly or non-uniformly to obtain a liquid resin. (A) and liquid resin (B) were prepared. While preparing each of the above liquid resins, a continuous production process of artificial marble described below was performed.

  First, the stainless steel belt 7 was moved at a speed of 46 mm / second using the molding cell 5 composed of the stainless steel belt 7 and the rubber frames 8 installed on both sides thereof. Then, a liquid resin (A) in which zinc oxide (colorant composition No. 1) is mixed as a pigment (a) is supplied onto the stainless steel belt 7 from the resin discharge port 9, and the lower layer (I ) Was formed. Here, the liquid resin (A) of the layer (I) flowed from the resin discharge port to the upstream portion of the molding cell 5 by about 0.3 m, and the liquid pool tip 12 was formed there. Subsequently, a liquid resin (B) mixed with titanium oxide (colorant composition No. 2) as a pigment (b) was injected in a stripe shape from the resin discharge port 10 onto the layer (I). A stripe layer (II) was formed. The liquid resin (B) of the layer (II) was laminated in stripes while hardly flowing back upstream from the resin discharge port 10 and spreading radially toward the downstream. The thickness of the layer (I) and the layer (II) in the laminated portion after reaching the steady state was about 7 mm.

  The distribution plate 13 was used as means for supplying the liquid resin (B) in a stripe shape. FIG. 4 is a schematic diagram showing the distribution plate. As shown in FIG. 4, the distribution plate 13 for forming the stripe is attached to the front end side of the resin discharge port 10 via the baffle plate 14. Further, a plurality of comb-like plates 15 are vertically arranged on the curved portion at the lower end of the distribution plate 13, whereby the liquid resin (B) is discharged onto the layer (I) in a stripe shape.

  Next, about 0.4 m downstream from the resin discharge port 10 for the liquid resin (B), the comb-like member 1 as shown in FIG. 2 is immersed in the layers (I) and (II) with the tips of the teeth. The layer (I) and the layer (II) are mixed by rotating in a horizontal direction with respect to the bottom surface of the molding cell 5 and simultaneously reciprocating in the width direction of the molding cell 5. A pattern was formed. As the comb-shaped member 1, specifically, one having 10 teeth made of polytetrafluoroethylene having a length of 200 mm, a width of 5 mm, and a thickness of 3 mm at intervals of 20 mm was used.

  A gauge roll 16 is provided on the downstream side of the installation portion of the comb-like member 1, and the surface of the liquid resin layer on which a desired pattern is formed is pressed by the gauge roll 16 to make the thickness uniform. Further, the liquid resin layer on which the desired pattern was formed was heated while being moved and cured to obtain an artificial marble having the desired pattern.

  The appearance of this artificial marble had a soft feeling because the boundary between the dark and light portions of the pattern was not conspicuous, and the pattern had almost no directionality, and had a texture like natural marble.

  The artificial marble obtained by the present invention is very useful, for example, for uses such as a kitchen top plate, a bathroom vanity, a bathtub, a table, a wall material, furniture, and interior accessories in a house.

It is a schematic diagram which shows an example of the state mixed with the comb-shaped member in this invention. It is a schematic diagram which shows an example of the comb-shaped member used for this invention. It is a schematic diagram which shows the continuous manufacturing apparatus of the artificial marble used in the Example. It is a schematic diagram which shows the distribution plate used in the Example.

Explanation of symbols

1 Comb-shaped member 2 layers (II)
3 layers (I)
4 teeth 5 molding cell 6 liquid resin supply means (distributor)
7 Stainless steel belt 8 Rubber frame 9 Resin outlet for liquid resin (A) 10 Resin outlet for liquid resin (B) 11 Unstirred mixer (static mixer)
12 Lead end of liquid reservoir 13 Distribution plate 14 Baffle plate 15 Comb-like plate 16 Gauge roll 17 Colorant supply pipe

Claims (2)

  The liquid resin (A) is injected into the molding cell to form the layer (I), and then the liquid resin (B) having a different color from the liquid resin (A) is striped on the layer (I). To form a stripe layer (II), and a pattern is formed by mixing layers (I) and (II) with a comb-like member, and then liquid resin (A) and liquid resin (B) are formed. The manufacturing method of the artificial marble which has a pattern including the process to harden | cure. The liquid resin (A) mixed with the pigment (a) is injected into the molding cell to form the layer (I), and then the liquid resin in which the pigment (b) is mixed on the layer (I). (B) is injected into a stripe shape to form a stripe layer (II), and the pattern is formed by mixing layers (I) and (II) with a comb-like member, and then the liquid resin (A) and The manufacturing method of the artificial marble which has a pattern including the process of hardening liquid resin (B).

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