JP2023133233A - Method for producing artificial basalt and artificial basalt produced thereby - Google Patents

Abstract

To provide a method for producing artificial basalt having a texture, appearance, and physical properties similar to natural basalt, and the artificial basalt produced thereby.SOLUTION: A method for producing artificial basalt according to the present invention includes: (S1) a step of producing a hard solidified urethane mixture by mixing polyurethane resin, ocher powder, pigment and water, and then stirring the expanded mixture by foaming with a wooden rod until foaming stops; (S2) a step of crushing the hard solidified urethane mixture produced in the above step (S1) into particles of 10 mm to 20 mm particle size with a crusher; (S3) a step of mixing the urethane particles crushed in the above step (S2) with polyurethane resin, ocher powder, pigment and water and stirring until foaming stops; and (S4) a step of producing artificial basalt by molding the mixture stirred in the above step (S3) until just before curing.SELECTED DRAWING: Figure 1

Description

The present invention relates to a method for producing artificial basalt and an artificial basalt produced by the method. More specifically, the present invention relates to a method for producing artificial basalt, and more specifically, it has a texture, appearance, and physical properties similar to natural basalt using polyurethane resin, loess powder, and pigment. The present invention relates to a method for producing artificial basalt that has a dramatically reduced weight, and to the artificial basalt produced by this method.

Basalt is a dark-colored or black fine-grained volcanic rock that is formed when lava cools rapidly and contains many irregularly shaped pores.It is widely used as a building material due to its unique appearance and unique atmosphere. ing. In particular, natural Jeju basalt is more expensive than concrete products, but due to its beautiful appearance, it is used for road boundary stones and sidewalk blocks, and is also used as interior and exterior materials as well as construction materials. Widely used.

Although natural basalt is more expensive than concrete products, due to its beautiful appearance, it is used for road boundary stones, sidewalk blocks, etc., and is also widely used as interior, exterior, and construction materials. There is.

However, when collecting and processing natural basalt, the cost is higher than that of concrete products, the range of processing is limited depending on the size of the rough stone, and the natural environment is damaged in the process of collecting natural basalt. Problems such as this occurred.

Although there have been many attempts to produce artificial basalt, most of them use natural basalt as a component or use materials such as Styrofoam to form pores, but environmental pollution still remains a problem. The shape of the produced artificial basalt is different from that of natural basalt, and no artificial basalt worthy of replacing natural basalt has yet been developed.

There have also been attempts to create an appearance similar to natural basalt using hard charcoal, but this is mainly used for air purification and antibacterial effects, and its mechanical strength is extremely poor. Because of this, it was difficult to use it as a building material for things like smoke tiles, sidewalks, and driveways.

Conventionally, the problem with producing artificial basalt is that additives such as pigments are required to create a texture similar to basalt, which complicates the production process and increases process costs.

Prior literature also discloses a technology for manufacturing artificial basalt by mixing aggregate, sand, stone powder, cement, pigment, admixture, and water and curing it using a silicone mold (Korean Registered Patent No. 10). -0466528), and other prior documents disclose techniques for producing artificial basalt using clay powder, crushed lignite, rice husks, and water (Korean Registered Patent No. 10-0790205), but the Although the technology used to express the texture of basalt while increasing the mechanical strength by using general aggregates, etc., it only showed the uneven texture on the surface by using a silicone mold, and it was difficult to reproduce the actual texture. The problem was that it was not able to display enough color to be mistaken for basalt.

Therefore, it has been desired to develop an artificial basalt that is similar in appearance to natural basalt, is easy to manufacture, and can be manufactured at low cost.

Korean Registered Patent No. 10-0466528 Korean Registered Patent No. 10-0790205

Therefore, the technical problem to be solved by the present invention is to provide a method for manufacturing artificial basalt that has texture, appearance, and physical properties similar to natural basalt, but has a dramatically reduced weight. .

Another technical problem to be solved by the present invention is to provide artificial basalt produced by the above production method.

In order to solve the above-mentioned technical problems, the present invention provides a method for producing artificial basalt, which includes the following steps.

(S1) After mixing the polyurethane resin, loess powder, pigment, and water, the mixture that expands due to foaming is continuously stirred with a wooden rod until the foaming stops, thereby producing a hard solidified urethane mixture;
(S2) Crushing the hard solidified urethane mixture produced in step (S1) into particles with a particle size of 10 mm to 20 mm using a crusher;
(S3) mixing the urethane particles crushed in the step (S2) with the polyurethane resin, loess powder, pigment, and water and stirring until foaming stops; and (S4) stirring in the step (S3). The stage of manufacturing artificial basalt by molding the mixture until just before hardening.

Preferably, in the above (S1), the polyurethane resin is a moisture-curable polyurethane resin.

Preferably, in step (S1), 50 to 70 parts by weight of loess, 25 to 35 parts by weight of pigment, and 8 to 12 parts by weight of water are mixed based on 100 parts by weight of the polyurethane resin.

Preferably, in the step (S3), the urethane particles are mixed with the mixture of polyurethane resin, loess powder, pigment, and water at a volume ratio of 4:6 to 6:4.

In order to solve the other technical problems mentioned above, the present invention provides artificial basalt produced by the above production method.

Preferably, the artificial basalt is one selected from the group consisting of a flower pot, a tray, a flower bed, an artificial coral reef, and a sidewalk tile.

As described above, since the artificial basalt produced according to the present invention has a texture, appearance, and physical properties similar to natural basalt, it is possible to produce artificial flower pots and trays with a natural stone texture using such artificial basalt. , can meet the requirements of consumer groups who prefer natural stone flower pots. Furthermore, the artificial basalt of the present invention has the advantage of dramatically reducing the heavy weight of natural stone flowerpots. Therefore, it is expected that the artificial basalt according to the present invention can be usefully used in various industrial fields as a substitute for expensive natural basalt.

The following drawings attached to this specification illustrate preferred embodiments of the present invention, and serve to facilitate understanding of the technical idea of the present invention together with the content of the invention described above. Therefore, the present invention should not be construed as being limited to only what is shown in the drawings.

It is a photograph showing an example of artificial basalt manufactured by the present invention. It is a photograph showing an example of artificial basalt manufactured by the present invention. It is a photograph showing an example of artificial basalt manufactured by the present invention. 1 is a test report showing the results of measuring the presence or absence of harmful substances in artificial basalt according to the present invention. FIG. 2 is a diagram showing an example in which artificial basalt according to the present invention is manufactured for use as an artificial coral reef in an aquarium.

The present invention provides a method for producing artificial basalt, which includes the following steps.

(S1) After mixing the polyurethane resin, loess powder, pigment, and water, the mixture that expands due to foaming is continuously stirred with a wooden rod until the foaming stops, thereby producing a hard solidified urethane mixture;
(S2) Crushing the hard solidified urethane mixture produced in step (S1) into particles with a particle size of 10 mm to 20 mm using a crusher;
(S3) mixing the urethane particles crushed in the step (S2) with the polyurethane resin, loess powder, pigment, and water and stirring until foaming stops; and (S4) stirring in the step (S3). The stage of manufacturing artificial basalt by molding the mixture until just before hardening.

In the present invention, after mixing liquid polyurethane resin, loess powder, pigment, and water, foaming occurs due to a chemical reaction after a certain period of time has elapsed, and the pattern of artificial basalt is created using the point at which hardening progresses after foaming. can be generated.

According to one embodiment of the present invention, the polyurethane resin is used as an adhesive.

Polyurethanes are derived from polyols and polyisocyanates. Examples of useful polyols include polyester polyols, polyether polyols, and combinations thereof. Useful polyester polyols include, for example, crystalline polyester polyols and amorphous polyester polyols.

The polyurethane may be in the form of an aqueous polyurethane dispersion, preferably an anionic polyurethane dispersion.

According to a specific embodiment of the present invention, the polyurethane resin is preferably a moisture-curable polyurethane resin.

The moisture-curing polyurethane resin can be produced by a conventional method known in the art, or a commercially available moisture-curing polyurethane resin can be used. Specifically, for example, a compound obtained by modifying a polyester polyol with caprolactam, a moisture-curable polyurethane resin consisting of a polyester polyol, an isocyanate, and a chain extender can be used, but the present invention is not limited thereto.

According to an embodiment of the present invention, based on 100 parts by weight of the polyurethane resin, 50 to 70 parts by weight of loess powder, 25 to 35 parts by weight of pigment, and 8 to 12 parts by weight of water are mixed.

The loess powder is the main material of basalt, and if the loess powder is used in an amount less than 50 parts by weight, basalt will not be formed properly, and if the loess powder is used in an amount exceeding 70 parts by weight, it may not mix well with other ingredients. The loess powder may be separated without adhesion.

The pigment used may be black, maroon, or a mixture of colors similar to those of natural basalt, but there are no particular limitations on this. If the pigment is used in an amount less than 25 parts by weight, the color of basalt will not appear, and if the pigment is used in an amount exceeding 35 parts by weight, the effect will not be proportional to the amount used. It is inefficient.

The water is used as one of the mixed materials for producing basalt. Here, if the amount of water is less than 8 parts by weight, there is a risk that the foaming time of the urethane material mixed during the production process of artificial basalt will be delayed, resulting in a longer working time. If water is used in an amount exceeding 12 parts by weight, the urethane mixture may be over-foamed and the texture and hardness of artificial basalt, which is the object of the present invention, may not be achieved.

According to an embodiment of the present invention, the polyurethane resin, loess powder, pigment, and water are placed in a container of a certain size, and while foaming, the expanding mixture is kept using a wooden stick until the foaming stops. Press while stirring. Thereafter, after foaming stops, curing begins, and when curing ends, a solidified urethane mixture can be obtained.

According to an embodiment of the present invention, by crushing the produced hard solidified urethane mixture into particles with a particle size of 10 mm to 20 mm using a crusher, the rough texture similar to that of natural basalt can be utilized. .

When the particle size of the solidified urethane mixture is less than 10 mm, it is difficult to exhibit a texture similar to natural basalt, and when the particle size of the solidified urethane mixture exceeds 20 mm, the basalt becomes too coarse. There is a risk.

According to an embodiment of the present invention, the urethane particles prepared in step (S3) are added to a mixture of polyurethane resin, loess powder, pigment, and water. At this time, the volume ratio of the urethane mixture to the urethane particles is preferably 4:6 to 6:4.

Here, if the above ratio is exceeded, it is difficult to exhibit a texture similar to that of natural basalt.

Further, as in step (S1), the mixture of the polyurethane resin, loess powder, pigment, and water is composed of 50 to 70 parts by weight of the loess powder, 25 to 35 parts by weight of the pigment, and 25 to 35 parts by weight of the water based on 100 parts by weight of the polyurethane resin. It is characterized by mixing 8 to 12 parts by weight.

A method for producing artificial basalt according to a specific embodiment of the present invention is characterized in that urethane particles are mixed into a mixture of liquid polyurethane, loess powder, pigment, and water, and then stirred until foaming stops. Here, the curing process is performed by performing heat generation and foaming process during the stirring process. Here, the mixing process is performed for 8 to 13 minutes to advance the foaming process.

The curing is performed within 1 to 5 minutes after foaming, and once hardened, the shape cannot be changed, so that artificial basalt can be manufactured by repeating the molding process until just before hardening.

According to a specific embodiment of the present invention, artificial basalt can be manufactured by molding the stirred mixture until just before hardening.

Here, the molding can be performed into a desired shape by using a mold or by kneading it by hand for a natural shape.

The molding using the mold can be pressure molding or injection molding, pressure molding is also called compression molding, and there are many types of presses, such as plaster molds, wooden molds, metal molds or other basic molds. It is a method of creating shapes using molds and molds, and is mainly used in the production of industrial ceramics.

The injection molding is a molding method in which a clay slurry is injected into a plaster mold and then poured out after a certain period of time to form the shape of a vessel within the plaster mold.

All the ranges mentioned above in the present invention are only the ranges necessary to form a shape close to natural basalt, and the content can be appropriately changed depending on the use of basalt.

The artificial basalt of the present invention can be manufactured by a curing process after passing through the forming step. Such a curing step can be accomplished by conventional methods known in the art.

Specifically, it is preferable to harden the shaped artificial basalt at a temperature of 10 to 20° C. for 30 to 50 minutes, and the curing stop (solidification phenomenon) time may vary depending on the temperature conditions. For example, when the temperature is 10°C, the stop time after the formation of artificial basalt is 50 minutes; when the temperature is 15°C, the stop time after the formation of the artificial basalt is 40 minutes; If the temperature is 20° C., the stopping time after the artificial basalt formation can be 30 minutes.

Meanwhile, the present invention provides artificial basalt manufactured by the above-described manufacturing method.

1 to 3 are photographs showing an example of artificial basalt produced according to the present invention.

The artificial basalt produced in the present invention can be used to supply oxygen to flower pots (moisture regulating effect when used in flower pots for bonsai, wild flowers, etc.), tray landscapes, flower beds (water absorbency, water discharge properties depending on temperature), and fish pots. It can be widely used for artificial coral reefs, daily necessities, sidewalk tiles (noise reduction, acupressure effect, anti-slip), building interior and exterior tiles (beautiful appearance), tourism products (stone halbang, etc.), etc.

As described above, since the artificial basalt produced according to the present invention has a texture, appearance, and physical properties similar to natural basalt, it is possible to produce artificial flower pots and trays with a natural stone texture using such artificial basalt. , can meet the requirements of consumer groups who prefer natural stone flower pots. Furthermore, the artificial basalt of the present invention has the advantage of dramatically reducing the heavy weight of natural stone flower pots. Therefore, it is expected that the artificial basalt according to the present invention can be usefully used in various industrial fields as a substitute for expensive natural basalt.

Hereinafter, the present invention will be described in detail based on examples to help understand the present invention. However, the embodiments of the present invention can be modified in various forms, and the scope of the present invention should not be construed as being limited to the following embodiments. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art.

<Example 1> Manufacture of artificial basalt 50 g of wet curing polyurethane resin, 30 g of loess powder, 10 g of maroon and black mixed pigments, and 5 g of water were mixed and pressed while continuously stirring with a wooden stick until foaming stopped. A solidified urethane mixture was produced. The produced solidified urethane mixture was crushed into particles having a particle size of 10 mm to 20 mm using a crusher.

Then, the polyurethane resin, loess powder, pigment and water should be further mixed, and the crushed urethane particles should be mixed in a volume ratio of 5:5, and the mixed material should be stirred for 5 minutes. After that, confirm with the naked eye the point at which foaming stops, and after manufacturing the artificial basalt in the shape you want to achieve from this point, leave it for 30 to 50 minutes until hardening has completely stopped, and check the hardness of the artificial basalt. We manufactured artificial basalt that has the texture of natural basalt. 1 to 3 are photographs showing an example of artificial basalt produced according to the present invention.

<Comparative example 1>
Artificial basalt was manufactured in the same manner as in Example 1 except that the urethane particles were not manufactured.

<Comparative example 2>
Artificial basalt was manufactured in the same manner as in Example 1, except that urethane particles were manufactured to have a particle size of 3 mm.

<Test Example 1> Bending Strength Measurement The bending strength of the artificial basalts of Example 1 and Comparative Examples 1 and 2 was measured and shown in Table 1 below. In Table 1, the unit of bending strength is kgf. For comparison, natural basalt was used as Comparative Example 3.

As shown in Table 1, the artificial basalt according to the present invention manufactured in Example 1 exceeded the standard value of flexural strength of 1,800. Therefore, it was found that the bending strength was comparable to that of Comparative Example 3, which is natural basalt.

<Test Example 2> Evaluation of physical properties (1) Porosity The surfaces of the artificial basalts of Example 1 and Comparative Examples 1 and 2 were observed with the naked eye to confirm how many pores were formed on the surface. was determined. Here, the size of the reference surface was width x length = 5 cm x 5 cm, and evaluation was made as follows using natural basalt as a reference.
◎: Similar to natural basalt, there are 20 or more pores in the standard area. ○: Similar to natural basalt, there are 10 to less than 20 pores in the standard area. △: Unlike natural basalt, there are 20 or more pores in the standard area. 3 or more and less than 10 pores exist ×: Unlike natural basalt, there are less than 3 pores in the standard area

(2) Roughness The surfaces of the artificial basalts of Example 1 and Comparative Examples 1 and 2 were touched and observed to determine the surface roughness. Here, evaluation was made as follows using natural basalt as a standard.
◎: Roughness similar to natural basalt ○: Roughness lower than natural basalt ×: Roughness higher than natural basalt

(3) Weight The weights of the artificial basalts of Example 1 and Comparative Examples 1 and 2 were measured, and the weights were determined based on natural basalts.
◎: Weight 1/6 to 1/5 of natural basalt ○: Weight 1/5 to 1/2 of natural basalt ×: Weight similar to natural basalt

As can be seen from Table 2, the artificial basalt produced according to the present invention had similar porosity and roughness to natural basalt, but the weight was reduced to less than 1/5.

<Test Example 3> Evaluation of generation of hazardous substances In order to confirm whether or not the artificial basalt of Example 1 is harmful, the artificial basalt manufactured in Example 1 was requested to the Korea Construction and Living Environment Testing Institute, and was certified under IEC62321- 5:2013, IEC62321-4:2013, IEC62321-7:2017, and IEC62321-6:2015, the presence or absence of hazardous substances was evaluated.

FIG. 4 is a test report showing the results of measuring the presence or absence of harmful substances in artificial basalt according to the present invention. As can be seen from FIG. 4, it was confirmed that no harmful substances including Pb, Cd, Hg, and Cr ⁶⁺ were detected in the artificial basalt according to the present invention.

<Test Example 4> Stability Evaluation In order to confirm the actual stability of the artificial basalt of Example 1, the artificial basalt manufactured in Example 1 was connected to a bubble generator and placed in an aquarium with live fish ( It was installed in water with a size of 620 mm x 330 mm x 500 mm and a water surface height (350 mm). FIG. 5 is a diagram showing an example of the artificial basalt according to the present invention manufactured for use as an artificial coral reef in an aquarium.

Even after more than two years had passed since the artificial basalt was placed in the aquarium, the growth of the fish was good during the experimental period, and the changes in the artificial basalt were the same as in the initial state.

Although specific portions of the present invention have been described in detail above, it will be understood by those skilled in the art that such specific techniques are merely preferred embodiments and that the scope of the present invention is limited thereto. It is clear that there is no limitation. It is therefore said that the substantial scope of the invention is defined by the appended claims and their equivalents.

Claims (6)

A method for producing artificial basalt,
(S1) After mixing the polyurethane resin, loess powder, pigment, and water, the mixture that expands due to foaming is continuously stirred with a wooden rod until the foaming stops, thereby producing a hard solidified urethane mixture;
(S2) Crushing the hard solidified urethane mixture produced in step (S1) into particles with a particle size of 10 mm to 20 mm using a crusher;
(S3) mixing the urethane particles crushed in the step (S2) with the polyurethane resin, loess powder, pigment, and water and stirring until foaming stops; and (S4) stirring in the step (S3). A method for manufacturing artificial basalt, comprising the step of manufacturing artificial basalt by molding the mixture until just before hardening. The method for producing artificial basalt according to claim 1, wherein in (S1), the polyurethane resin is a moisture-curable polyurethane resin. According to claim 1, in the step (S1), based on 100 parts by weight of the polyurethane resin, 50 to 70 parts by weight of loess, 25 to 35 parts by weight of pigment, and 8 to 12 parts by weight of water are mixed. Method of manufacturing artificial basalt. According to claim 1, in the step (S3), the urethane particles are mixed with the mixture of polyurethane resin, loess powder, pigment, and water at a volume ratio of 4:6 to 6:4. Method of manufacturing artificial basalt. Artificial basalt produced by the production method according to any one of claims 1 to 4. The artificial basalt according to claim 5, wherein the artificial basalt is one selected from the group consisting of a flower pot, a tray, a flower bed, an artificial coral reef, and a sidewalk tile.