JP2807492B2 - Decorative plate with stone pattern and method for producing the same - Google Patents

Description

Description: TECHNICAL FIELD The present invention relates to a decorative board with a stone pattern used mainly on an indoor floor or a wall surface of an office, a station, an underground shopping mall, or other public facilities, and a method for producing the decorative board.

(Conventional technology) In recent years, stone-like decorative boards made by hardening natural gravel with resin or cement and polishing the surface to expose the cut surface of the gravel are widely used as building interior and exterior materials or pavement materials. It was started. Also, the applicant of the present invention has disclosed in Japanese Patent Application No. 61-170488 (Japanese Patent Application Laid-Open No. 63-027246) a stone obtained by laminating a natural stone slice plate on a flame-retardant inorganic substrate layer with an adhesive or the like. An inorganic decorative panel with tones was proposed. Since these decorative boards have the texture of natural stone, they have excellent decorative effects,
The practical value in the above applications is highly evaluated.

(Problems to be Solved by the Invention) By the way, the decorative board obtained by solidifying the above natural sand and gravel with a resin is obtained by mixing natural sand and sand with a synthetic resin, filling the mixture into a predetermined mold, hot pressing, and then pressing the surface. Is made by polishing. Unless the surface is evenly distributed after filling the mold, so-called one-sided tightening (roughness / tightness) is performed by a subsequent hot press, and the quality varies. Since such leveling work is generally performed manually, it requires labor and labor, which is a major factor impairing the manufacturing efficiency, and also causes artificial quality variation.

In addition, in the case where the above-mentioned sliced stone plate and the inorganic substrate layer are laminated, it is necessary to slice and cut the natural stone into a thickness of 1 to 5 mm. In this case, it is necessary to pay close attention to the above, and there is also a problem in terms of manufacturing efficiency.

The present invention has been made in view of the above, and an object of the present invention is to provide a novel decorative stone-plated board having a constant product quality and which can be efficiently manufactured, and an effective manufacturing method thereof.

(Means for Solving the Problems) The present invention will be described with reference to the accompanying drawings. FIG. 1 is a perspective view showing an embodiment of the decorative board of the present invention, FIG. 2 is a longitudinal sectional view of the embodiment, FIG. 3 is a view similar to FIG. 2 of another embodiment, and FIG. FIG. 5 is a process chart showing an example of the manufacturing method, and FIG. 5 is a process chart of another embodiment.

That is, the decorative board 1 with a stone pattern according to the first embodiment of the present invention.
Is composed of natural sand and gravel aggregate 11 and synthetic resin binder 12 as main components. Temporarily press-mold the mixture of these with an extruder, hot press, and grind the surface. It is the gist.

In addition, the stone-patterned decorative board 1 ′ according to the second embodiment is composed of an inorganic base layer 2 containing aluminum hydroxide as a main aggregate and a flame-retardant thermosetting resin binder, and an aggregate of natural gravel. 11
And the surface layer portion 1 containing a flame-retardant thermosetting synthetic resin binder 12 'as a main component and the surface layer portion 1 are integrally laminated by a hot press, and the surface thereof is polished.

Further, the method for producing a stone-patterned decorative board according to the present invention,
The natural sand and gravel aggregate 11 and the synthetic resin binder 2 are mixed as the main components, and the mixture 10 is temporarily formed into a plate shape by the extruder 4.
After 100, hot pressing 5 is performed, and the surface is polished.

The above-mentioned aggregates 11 are natural gravel (including crushed stones) produced in mountains, rivers or coasts, and are used in a grain size of 0.5 to 1.5 mm, preferably 1 to 9 mm. If the particle size is less than 0.5 mm, even if it is polished, the cut surface of each gravel will not be exposed, and the stone-like feeling will not appear.If the particle size exceeds 15 mm, it will be difficult to uniformly mix with the binder, It is necessary to make the gap between the screw and the cylinder of the extruder 4 larger,
This is because extrusion becomes difficult.

As the binder 12 (12 '), a polyester resin is most desirable from the viewpoint of transparency, but a resin such as a phenol resin, a melamine resin, an acrylic resin, and a polydiphenyl oxide resin and a derivative thereof can also be used. In particular, as the flame-retardant thermosetting synthetic resin binder 12 ′ according to the second embodiment,
These thermosetting resins except polyester resin and acrylic resin are used.

When the mixture of the aggregate 11 and the binder 12 is temporarily formed into a plate by the extruder 4, a thickener such as magnesium oxide, calcium oxide, beryllium oxide, calcium hydroxide, zinc oxide, etc. is added. It is desirable. This is for the purpose of improving shape retention and extrudability during temporary molding. In addition, a lubricant or a coupling agent for improving extrudability and various properties of the decorative plate 1, calcium carbonate, silica sand, calcite powder,
It is also possible to appropriately add an inorganic extender such as calcium silicate powder, a coloring pigment and the like.

In the admixture containing the above-mentioned aggregate and synthetic resin binder as main components, the aggregate is 60 to 90% by weight, the binder is 5 to 20% by weight, and when a thickener is used, 0.1 to 3.0% by weight (preferably 0.3-0.7
% By weight). When the amount of the aggregate is less than 60% by weight, the amount of the aggregate exposed on the surface is reduced, and no stone pattern is exhibited. On the other hand, when the amount is more than 90% by weight, the binding force of the binder is weakened. If the amount of the binder is less than 5% by weight, the bonding strength is weak, and if it exceeds 10% by weight, the resin becomes rich and the stone-like feeling is reduced. Further, when the thickener is less than 0.1% by weight, the thickening effect is not sufficient, and when it exceeds 3.0% by weight, extrusion molding becomes difficult.

The inorganic base layer portion 2 in the decorative plate according to the second embodiment has aluminum hydroxide (Al ₂ O ₃ .3H ₂ O) as a main aggregate,
As auxiliary aggregates, calcium carbonate, silica sand, calcite powder, calcium silicate, zeolite, kaolin, bentonite,
Acid clay is also used. Further, as a reinforcing material, mineral fiber (asbestos, etc.), inorganic fiber (glass fiber, ceramic fiber, etc.), metal fiber (iron fiber, aluminum fiber, whisker, etc.), natural fiber (cotton, hemp cotton, etc.), synthetic chemical fiber Fiber chops (vinylon, nylon, tetron, etc.) may also be used. The flame-retardant thermosetting resin described above is used as the flame-retardant curable binder in this embodiment.

The aluminum hydroxide powder serves as a mechanical strength material for the base layer 2 and is added in an amount of 40 to 97% by weight (preferably 50 to 85% by weight) based on the total amount. Although it does not change, when the ambient temperature becomes 300 to 500 ° C., it releases crystallization water and suppresses combustion, and at the same time becomes Al ₂ O ₃ as a heat-resistant material, so that the base layer portion 2 is given semi-flammability or non-flammability. . If the compounding amount is less than 40%, it becomes insufficient to obtain quasi-flammability, while if it exceeds 97%, the bonding strength decreases,
The above-mentioned 50 to 85% is a desirable range. However, in order to provide non-combustibility, it is necessary to mix about 70-97%.

The auxiliary aggregate is used to improve the mechanical strength of the base layer 2 and reduce the cost by increasing the amount, or as an auxiliary binder and for imparting fluidity and increasing the amount of fluid at the time of molding. If the amount is not more than 77% and exceeds 77%, the nonflammability is impaired, and the range of 15 to 45% is a desirable range.

Reinforcing material is used to further improve the mechanical strength of the base layer 2 and is added up to 15%, preferably 2-10%.

The binder is a flame-retardant thermosetting resin which gives molding fluidity to each of the above-mentioned materials and can be cured by hot pressure, and its use amount is 3 to 12%. If the amount is less than 3%, the bonding strength will be insufficient, while if it exceeds 12%, even if the amount of aluminum hydroxide is large, it cannot be used as a non-combustible material. Desirably, it is 6 to 10%.

On the back surface of the base layer portion 2, a reinforcing layer 21 or a backing layer 22 or the like for preventing reinforcement or warping of the base layer 2 is used. As the reinforcing layer 21, a cloth net of glass fiber or the like is used. The backing layer 22 is formed by impregnating and drying a fibrous base material with a thermosetting resin or a thermoplastic resin. The reinforcing layer 21 and the backing layer 22 are used alone or in combination, and are integrated with the back surface of the base layer portion 2 during the hot pressing.

(Operation) For convenience, the inventions according to the first embodiment and the third embodiment will be described together. The stone-patterned decorative board 1 in this embodiment is a mixture mainly composed of natural sand and gravel aggregates 11 and a synthetic resin binder 12.
10 is preliminarily formed into a plate shape by the extruder 4 and then obtained by hot pressing 5. Before the hot pressing 5, the plate 10 is extruded into a plate-like body 100 having a uniform shape. No leveling work is required. In addition, as a result of eliminating the need for such artificial work, there is no variation in the shape due to work unevenness, and after hot pressing 5, the aggregates 11 and the binder 12 are compacted and compacted to obtain uniform and uniform quality. Molded board 100a
Is obtained. Then, when the surface of the molded plate 100a is polished, bones 11... Located on the surface portion are cut, and this is glimpsed in the polished surface of the hardened layer by the binder 12, giving a feeling like a stone.

Further, in the decorative panel according to the second embodiment, the inorganic base layer 2 bonded with a flame-retardant thermosetting synthetic resin binder using aluminum hydroxide as a main aggregate, and an aggregate of natural gravel
11 ... and the flame-retardant thermosetting synthetic resin binder 12 'and the surface layer 1 polished on the surface of the hot-press molded body 100a are integrally laminated, so that the surface has the same feeling as stone as above. In addition to this, the whole becomes quasi-nonflammable or non-flammable, and is suitable as an interior material of a building. In addition, the base layer 2 and the surface layer 1 are very firmly integrated by mutual fusion and hardening of the thermosetting synthetic resin binder contained therein during the hot pressing, and there is a concern about peeling between the layers. Does not occur.

(Example) Next, an example is described.

(Example-1) ... see Fig. 4 (i) Preparation of raw materials for decorative board with stone-tone pattern;

(Ii) Temporary molding: The above prepared product was mixed with the mixer 3 and extruded with the extruder 4 to obtain a plate-shaped temporary molded product 100. This temporary molded product 100
In this case, the binder 12 was not completely filled between the aggregates 11, so that it was porous, and irregularities due to the voids remained on the surface.

(Iii) Hot press molding: The above temporary molded product 100 is introduced into a hot press 5 and heated at 150 ° C. and 200 k
It was hot pressed at g / cm ² for 10 minutes. Here, the binder 12 was completely filled between the aggregates 11 and cured to obtain a hot press molded product 100a having a dense and flat surface.

(Iv) Polishing of the surface: The surface of the hot press molded article 100a was polished by a polishing machine to about 2 mm. In the obtained polished product 1, the aggregates 11 on the surface portion were cut, and these were scattered in the hardened layer of the binder 12, giving a feeling like a stone.

(Example-2) See FIG. 5 (i) Preparation of base layer material: The base layer material was prepared according to the composition shown in Table 2 below.

(Ii) Preparation of surface layer material: The surface layer material was prepared according to the composition shown in Table 3 below.

(Iii) Lamination of base layer material and surface layer material; 120 g / m ² of kraft paper is immersed in a melamine resin solution, and then dried to impregnate and carry 150% (180 g / m ² ) of melamine resin. The backing material 22 was placed on the belt conveyor 7, and the glass net 21 was further superimposed thereon. The base layer material 20 is kneaded with a co-kneader 6 and continuously supplied to the backing material 22 and the glass net 21 on the belt conveyor 7 so as to have a constant layer thickness. Leveled. Further, the surface layer material 10 mixed by the mixer 3 is continuously supplied so as to have a constant layer thickness on the base layer material 20 which is continuously fed while being leveled, and the surface thereof is lightened by a roll 72. Pressed and leveled.

(Iv) Hot press molding; The laminar product 100 'is introduced into the hot press 5 at regular intervals,
Hot pressing was performed under the same conditions as above. Here, the base layer portion 2 and the surface layer portion 1 are completely hardened together with the backing material 22 and the glass net 21. In the surface layer portion 1, the binder 12 'is completely filled between the aggregates 11 and the surface is flat. Hot press molding 10
0a 'was obtained.

(V) Surface polishing: The surface of the hot press molded product 100a 'was polished by a polishing machine to about 2 mm. The obtained polished product 1 'is made of the aggregate 11 on the surface.
.. Were cut and found in the hardened layer of the binder 12 ', giving a feeling like a stone. The polished product 1 'passed the nonflammable material sufficiently.

It is needless to say that the present invention is not limited to the above embodiment, and that other modifications can be made without departing from the present invention.

(Effect of the Invention) As described above, in the stone-patterned decorative board and the method of manufacturing the same according to the first and third aspects of the present invention, the admixture of aggregate of natural gravel and a synthetic resin binder is used. Since it is hot-pressed after being extruded into a plate shape, leveling work before pressing is unnecessary, and a decorative board of a uniform quality that is uniformly compacted can be obtained, thereby increasing production.

In addition, in the case of the decorative board according to the second embodiment, the raw materials of the base layer and the surface layer are prepared, and they are laminated and integrated by hot pressing. The yield does not decrease due to the occurrence of cracks. Moreover, since both layers are flame-retardant, they can be used as semi-flammable or non-flammable building boards.

Also, in any of the decorative boards, the cut surface of the aggregate is exposed on the polished surface, and together with the hardened layer of the binder resin, it presents a feeling like a natural stone material, replacing the natural stone material. Its practical value as an indoor floor material or wall material is extremely large.

[Brief description of the drawings]

FIG. 1 is a perspective view showing an embodiment of the decorative board of the present invention, FIG. 2 is a longitudinal sectional view of the embodiment, FIG. 3 is a view similar to FIG. 2 of another embodiment, and FIG. FIG. 5 is a process chart showing an example of the manufacturing method, and FIG. 5 is a process chart of another embodiment. (Explanation of reference numerals) 1, 1 ': decorative board with stone pattern (surface layer), 11: aggregate, 12, 12': synthetic resin binder, 2: base layer, 4 ...
... extruder, 5 ... hot press.

Claims (4)

(57) [Claims] 1. A stone comprising an aggregate of natural gravel and a synthetic resin binder as a main component, a mixture of these being preliminarily molded in an extruder, hot pressing, and polishing the surface. Tone with decorative pattern. 2. An inorganic base layer comprising aluminum hydroxide as a main aggregate and a flame-retardant thermosetting resin binder,
A stone-patterned decorative board made by laminating and integrating a natural sand and gravel aggregate and a surface layer containing a flame-retardant thermosetting synthetic resin binder as a main component by a hot press and polishing the surface. 3. A method in which aggregates of natural sand and gravel and a synthetic resin binder are mixed as main components, and the mixture is provisionally formed into a plate by an extruder, and then hot pressed to grind the surface. A method for producing a decorative board with a stone pattern. 4. The method according to claim 3, wherein the mixture of the aggregate and the binder further comprises a thickener.