JP2920581B2 - Manufacturing method of artificial stone - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing artificial stone used as a counter, a wall panel, a floor panel, or the like installed in a kitchen, a dressing room, a bathroom, or the like.

[0002]

2. Description of the Related Art Conventionally, counters made of artificial stone having the same appearance as natural stones such as granite and marble have been widely used in kitchens, dressing rooms and the like. Conventionally, such artificial stones include resins such as unsaturated polyester resin, polymethyl methacrylate resin (acrylic resin),
It is manufactured by kneading a filler composed of aluminum hydroxide, calcium carbonate, glass frit, and the like, a curing agent, a pigment, additives, and the like to form a slurry, and then injecting the slurry into a mold and curing.

[0003]

By the way, such a counter made of artificial stone is cut through the above-mentioned hardened step, and then cut into the above-mentioned counter in order to obtain a size corresponding to the length of a dressing room to be installed. Although the product is completed after the step of performing, a large amount of artificial stone as waste material that is not made into a product is generated, such as a cut piece generated by such cutting, or a defective product having cracks or chips. Conventionally, such artificial stones as waste materials have been discarded as industrial waste, but it is desirable to recycle them from the viewpoint of the recent legal regulations on industrial waste and effective use of resources. Therefore, as a method of reusing the artificial stone generated as a piece or a defective product, the artificial stone is crushed or crushed, and the crushed artificial stone is mixed with the filler and kneaded with a resin or the like. It can be considered that the artificial stone is formed again by forming and hardening the slurry after forming the slurry. However, in the case of using this method, not only bubbles are easily left between the crushed artificial stone and the slurry, but also the wettability between the crushed artificial stone and the slurry is poor, and the connection of the interface is weak. ,
The mechanical strength of an artificial stone newly manufactured using artificial stone as waste material is extremely low.

Therefore, the present invention has been proposed in order to solve the problems of the above-described method for producing artificial stone, and it is possible to effectively reuse artificial stone which has been conventionally discarded. It is an object of the present invention to provide a method for manufacturing artificial stone that can make the mechanical strength of newly manufactured artificial stone extremely high.

[0005]

Means for Solving the Problems The present invention is, again be those proposed in order to achieve the above object, a step of pulverizing the human <br/> Tsukuriishi be reused, which is the pulverized A step of dipping in a part of the monomer constituting the resin used as a raw material of the artificial stone to be used, and the pulverized and reused artificial stone from within the monomer. A filtering step, and the filtered and reused artificial stone, and a raw material of the newly manufactured artificial stone, and at least the recycled artificial stone material
Kneading, molding and curing the same resin and the same resin .

Here, in the first step of pulverizing the artificial stone to be reused , a pulverizer such as a roll mill or a ball mill may be used as appropriate. In addition, the particle size of the crushed artificial stone uses 1 μm to 2000 μm. However, if the amount of fine powder is large, it is not possible to expect a large amount to be added. For such reasons, the thickness is preferably 10 μm to 500 μm.
In the second step of immersing the crushed artificial stone in the monomer, the monomer is reused.
Composing the resin used as the raw material for the crushed artificial stone
Some monomers , i.e., a styrene monomer when the resin constituting the pulverized artificial stone is an unsaturated polyester resin, and a methyl methacrylate monomer when the resin is a polymethyl methacrylate .
By immersing the crushed and reused artificial stone in such a monomer, the surface of the artificial stone swells, and the wettability with other raw materials is improved in the subsequent molding and curing steps. The time for immersing the crushed artificial stone in such a monomer may be at least as long as the surface of the crushed artificial stone can sufficiently swell, and usually requires 24 hours or more of immersion time. After the step of dipping in the monomer is completed, the third step
In the step (3), the pulverized and recycled artificial stone is filtered from the above-mentioned monomer, then kneaded with other raw materials to form a slurry, and then molded and hardened using a molding die. As a result, a new artificial stone including the artificial stone that has been conventionally discarded is manufactured. The other raw materials mentioned here are
A filler, a resin, a curing agent, a curing accelerator, or the like generally used as a raw material of a conventional artificial stone may be used, and in some cases, a pigment or the like may be used. In the case of manufacturing artificial stones such as granite, it is possible to use a substance having a similar bending ratio to a resin, such as aluminum hydroxide, aluminum silicate, glass frit, etc. as a filler. preferable. By using a material having a similar flexural modulus to resin , a newly manufactured artificial stone can be given a certain degree of translucency, making it a three-dimensional artificial stone that is closer to natural stone. Can be.
As for the resin which is one of raw materials, recycled
It is necessary to use at least the same resin as the resin constituting the ground (reused) artificial stone from the viewpoint of securing the mechanical strength with the ground artificial stone to be ground. As the curing agent, one generally used conventionally, for example, benzoyl peroxide may be used. If necessary, a curing accelerator such as cobalt naphthenate may be used in combination. If it is necessary to smooth the surface of the newly manufactured artificial stone, first apply a gel coat resin to the mold, and then crush the artificial stone whose surface has swelled by immersion in the monomer. the is molded and cured by placing the slurry in which the other ingredients are mixed <br/> input. The crushed artificial stones (reused artificial stones) are not only artificial stones formed and hardened only with new raw materials, but also undergo the above-described steps (using recycled artificial stones). It may be formed and hardened artificial stone.

[0007]

According to the method for producing artificial stone according to the present invention, not only can artificial stone conventionally used as industrial waste be effectively used, but also as described above, the artificial stone is pulverized in the first step. By immersing the artificial stone in a predetermined monomer in the second step, the surface of the pulverized artificial stone swells, and the swollen artificial stone is kneaded with other raw materials, molded and hardened. This greatly contributes to the polymerization of the pulverized artificial stone and the resin as another raw material, whereby an extremely large mechanical strength can be secured. In addition, since the specific gravity of the crushed artificial stone and the other raw materials are close to each other, after the crushed artificial stone and the other raw materials are kneaded and put into a molding die, they are separated from each other. Danger can be reduced.

[0008]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Embodiments in which the method for manufacturing artificial stone according to the present invention is applied to a method for manufacturing a counter will be described in detail with reference to the drawings in the order of each step.

First, as shown in FIG. 1, an artificial stone 1 generated as a piece or a defective piece of a counter or the like is first made into a coarse pulverized product 2 by using a first pulverizer 3, Is used to obtain a pulverized material 5 having a particle size of about 10 μm to 500 μm.

Next, the pulverized product 5 obtained by the above process
Into a container 7 filled with monomer 6 as shown in FIG.
And immersed for about 24 hours. The artificial stone 1
Is a polyester resin, the styrene monomer is used as the monomer 6. In this step, the surface of the pulverized material 5 swells. After the immersion in the monomer 6 is completed, the monomer 6 and the pulverized material 5 are filtered using a filter (not shown).

After the filtration step of the pulverized material 5 is completed, the unsaturated polyester resin 1 having a viscosity of 800 cps is
00 parts by weight, 0.5 parts by weight of 0.6% cobalt naphthenate as a hardening accelerator, 1 part by weight of methyl ethyl peroxide as a hardening agent, and 150 parts by weight of aluminum hydroxide as a filler. Then, the above crushed material 5 is added to 10
And 0 parts by weight to form a slurry. Then, as shown in FIG. 3, a gel coat resin 12 is applied to the forming surface of the counter mold 10 using a gel coat application device 11. After the step of applying the gel coat resin 12 is completed, a split mold 13 is attached to the molding die 10 as shown in FIG.
After that, it is hardened and demolded. As shown in FIG. 3, the forming die 10 used for manufacturing the counter made of artificial stone has a constant length, while the length of the counter installed and fixed in a dressing room or the like is as follows. Since it is necessary to have a predetermined length corresponding to the place to be installed and fixed, a step of cutting one end side is required after the above-mentioned demolding step to obtain a predetermined length. However, a gel coat layer is not formed on the cut surface thus cut, and a step of forming a new gel coat layer is required. Therefore, in order to omit such a step and shorten the counter manufacturing time, FIG. Mobile type 20 shown in
It is desirable to use The movable die 20 is formed on the molding die 10 shown in FIG. 3 and can be placed on a molding surface 10a having a substantially crank-shaped side surface. The length of the counter corresponding to the place to be installed and fixed by appropriately moving the counter is formed. In FIG. 5, a portion indicated by reference numeral 21 is a first forming surface for molding the side surface of the flat portion of the counter to be manufactured. The first forming surface is continuous with the first forming surface 21 and has an L-shape. The upstanding surface is a second molding surface 22 for molding the side surface of the apron portion of the counter, and the surface hanging downward from the first molding surface 21 is a third molding surface for molding the side surface of the back guard of the counter. Molding surface 23
It is. As shown in FIG. 6, the movable mold 20 includes a center layer 20a made of wood, and a surface layer 20b formed on the surface of the center layer 20a and made of a silicone resin. The first to third molding surfaces 21, 22, 23 are formed with tapered portions 21a, 22a, 23a each having a substantially arc-shaped cross section. Therefore, the above-mentioned movable mold 20 configured as described above is used.
Into the mold 10 shown in FIG. 3 (two if necessary)
After placing and applying the gel coat resin 12 thereon,
By pouring the slurry 14 as shown in FIG. 4, it is not necessary to cut one end after curing and demolding as described above, and the gel coat layer 15 is also provided on the side surface of the counter 14 as shown in FIG. Since it is formed, the step of applying a gel coat resin after cutting can also be omitted.

A gel coat layer 15 is formed on the surface by the above-described series of steps, and as shown in FIG. 8, a new artificial man-made stone 1 into which a crushed material 5 of the artificial stone 1 which has been conventionally discarded is mixed. Stone counters are manufactured.
In particular, since the surface 5a of the pulverized material 5 is swollen by being immersed in the styrene monomer 6, no air bubbles remain on the surface of the pulverized material 5 and polymerization with the unsaturated polyester resin 17 occurs. Is good, and thus a counter having sufficient mechanical strength can be obtained. In addition, since the crushed material 5 of the artificial stone 1 does not change its specific gravity much as compared with other raw materials, the crushed material 5 is poured into a molding die 10 after being made into the slurry, and before being hardened.
The pulverized material 5 and other raw materials are not separated from each other.

As described above, if a counter made of artificial stone is manufactured by the process according to the present embodiment, not only the artificial stone 1 conventionally used as industrial waste can be effectively used, but also as described above. In the second step, the crushed material 5 obtained in the first step is
The swelled pulverized material 5 is swelled by being immersed in the material, and the swollen pulverized material 5 is kneaded with other raw materials and molded and cured to form the pulverized material 5 and one of the other raw materials. This contributes to the polymerization with the unsaturated polyester resin 17, whereby an extremely large mechanical strength can be secured. In addition, a crushed product 5 of the artificial stone 1
Since the specific gravities of the pulverized material 5 and the other raw materials are close to each other, the risk that the pulverized material 5 and the other raw materials are separated from each other after being kneaded and put into a molding die can be reduced.

In the above embodiment, the resin constituting the artificial stone 1 to be pulverized (reused) is an unsaturated polyester resin and is the same as one of the raw materials of the artificial stone to be newly manufactured. Since a saturated polyester resin is used, a styrene monomer is used as a monomer for immersing the pulverized material.However, the present invention at least uses a resin which is one of the raw materials of a newly manufactured artificial stone and an artificial stone to be reused. Other monomers may be used as long as the polymerization with the pulverized product can be sufficiently achieved. Therefore, for example, when the resin constituting the artificial stone to be reused and the resin used as a raw material of the artificial stone to be newly manufactured are polymethyl methacrylate resins, a methyl methacrylate monomer may be used.

Further, in the above-described embodiment, an example in which the method of manufacturing an artificial stone according to the present invention is applied to a method of manufacturing a counter has been described. However, the present invention is not necessarily limited to the case where the method is applied to the above-described method of manufacturing a counter. Not necessarily, it may be an article or part manufactured as a roughly artificial stone, for example,
It may be applied to a wall panel, a floor panel, a table top plate, or the like.

[0016]

As is clear from the description of each of the above embodiments, according to the method for producing artificial stone according to the present invention, artificial stone conventionally used as industrial waste can be effectively utilized. Rather, as described above, by immersing the artificial stone crushed in the first step in a predetermined monomer in the second step, the surface of the crushed artificial stone swells. By kneading and molding and hardening the artificial stone together with other raw materials, it greatly contributes to the polymerization of the pulverized artificial stone and the resin as another raw material, thereby ensuring extremely high mechanical strength. Can be. In addition, since the specific gravity of the crushed artificial stone and the other raw materials are close to each other, after the crushed artificial stone and the other raw materials are kneaded and put into a molding die, they are separated from each other. Danger can be reduced.

[Brief description of the drawings]

FIG. 1 is a perspective view schematically showing a step of grinding artificial stone.

FIG. 2 is an end view schematically showing a step of immersing crushed artificial stone in a monomer.

FIG. 3 is a perspective view schematically showing a step of applying a gel coat resin to a counter mold.

FIG. 4 is a perspective view schematically showing a step of pouring a slurry into a molding die.

FIG. 5 is a perspective view showing an appearance of a movable type.

FIG. 6 is a cross-sectional view taken along line AA of the movable type shown in FIG. 5;

FIG. 7 is a cross-sectional view showing a main part in a state where the gel coat resin and the slurry are molded and cured.

FIG. 8 is an explanatory view schematically showing, in an enlarged manner, a state in which the crushed artificial stone has been hardened together with another material.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Artificial stone 2 Crusher 5 Artificial stone crushed material 6 Monomer 10 Mold 14 Slurry 17 Unsaturated polyester resin

Claims (1)

(57) [Claims] 1. A a step of pulverizing the artificial stone to be reused, has been made with the material of the artificial stone to be recycled is above pulverization
Immersing a portion of the monomers constituting the that resin, a step of filtering the artificial stone to be recycled is the milled from the inside monomer, and artificial stone, which is recycled this is filtered, freshly prepared Is
The person to be at least the re-use of a raw material of that artificial stone
A step of kneading, molding and curing the same resin as the resin used as the raw material of the stone, and forming and curing the artificial stone.