JP3006955B2 - Manufacturing method of stone board - Google Patents
Manufacturing method of stone boardInfo
- Publication number
- JP3006955B2 JP3006955B2 JP4102826A JP10282692A JP3006955B2 JP 3006955 B2 JP3006955 B2 JP 3006955B2 JP 4102826 A JP4102826 A JP 4102826A JP 10282692 A JP10282692 A JP 10282692A JP 3006955 B2 JP3006955 B2 JP 3006955B2
- Authority
- JP
- Japan
- Prior art keywords
- stone
- thermosetting
- manufacturing
- composition
- cement
- 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.)
- Expired - Fee Related
Links
Landscapes
- Panels For Use In Building Construction (AREA)
- Laminated Bodies (AREA)
- Producing Shaped Articles From Materials (AREA)
Description
【０００１】[0001]
【産業上の利用分野】本発明は、建築物の内装又は外装
等に用いられる板材の製造方法に係り、特に石材のよう
な外観の表面を有するとともに、軽量で加工が容易な石
材調板材の製造方法に関する。BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a plate material used for the interior or exterior of a building, and more particularly to a method for manufacturing a light-weight, easy-to-process stone material having a surface like stone. It relates to a manufacturing method.
【０００２】[0002]
【従来の技術】近年、一般住宅や店舗等の木造建築物に
おいても石材を使用することが増加している。石材は重
量感を有するとともに高級感をもたらすことから好んで
用いられるものである。2. Description of the Related Art In recent years, stone materials have been increasingly used in wooden buildings such as ordinary houses and shops. Stone is preferably used because it has a sense of weight and gives a sense of quality.
【０００３】上記のように建材として用いられる石材に
は、自然石の他、粉砕石をセメント等で固めたテラゾと
呼ばれるものもあるが、いずれも重量が大きいこと、加
工が難しいこと等の欠点を有している。As described above, stones used as building materials include natural stones and terrazzos obtained by solidifying crushed stones with cement or the like. However, all of them have drawbacks such as heavy weight and difficulty in processing. have.
【０００４】このような欠点を補うものとして、特開平
３−７５２５０号公報に開示される石材調建材がある。
この石材調建材は、天然石を粉砕した石片を伸び率の高
い高分子材料をバインダーとして板状に固結したもので
あり、天然石のような外観を有するとともに、薄く形成
することができ、加工が容易で釘を打ち付けること等も
できる。To compensate for such a disadvantage, there is a stone-like building material disclosed in Japanese Patent Application Laid-Open No. 3-75250.
This stone-like building material is obtained by consolidating stone pieces obtained by pulverizing natural stone into a plate shape using a high-elongation polymer material as a binder, has the appearance of natural stone, and can be formed thinly. Is easy, and nails can be driven.
【０００５】[0005]
【発明が解決しようとする課題】しかしながら、上記特
開平３−７５２５０号公報に記載の石材調建材では、石
片と高分子材料とを一緒に型内に供給し、高分子材料の
硬化後脱型することによって得られるものであり、注型
後硬化するまでに時間がかかって生産性が悪い。また、
石片と高分子材料とからなる層を他の基板と積層して形
成した石材調建材も開示されているが、この製造は、未
硬化の高分子材料と石片とを型内に供給した後基板とな
る板材を載置し、密着させた状態で高分子材料が硬化す
るのを待つものである。したがって、高分子材料の硬化
に時間がかかるのに加え、基板となる板材を別途の工程
で制作しておかなければならず、多くの生産工程を要し
て生産コストも高くなる。However, in the stone preparation material described in Japanese Patent Application Laid-Open No. 3-75250, stone pieces and a polymer material are supplied together into a mold, and after the polymer material is cured, the material is removed. It is obtained by molding, and it takes a long time to cure after casting, resulting in poor productivity. Also,
A stone building material formed by laminating a layer made of stone pieces and a polymer material with another substrate is also disclosed, but in this production, an uncured polymer material and a stone piece were supplied into a mold. This is to wait for the polymer material to harden in a state where a plate material to be a rear substrate is placed and adhered. Therefore, in addition to the time required for curing the polymer material, a plate material to be a substrate must be produced in a separate process, which requires many production steps and increases the production cost.
【０００６】本発明は、上記のような問題点に鑑みてな
されたものであり、その目的は、石材のような外観を有
し軽量で加工が容易な板材を、安価で効率良く量産する
ことができる石材調板材の製造方法を提供することであ
る。The present invention has been made in view of the above-mentioned problems, and an object of the present invention is to mass-produce a plate material having an appearance like a stone material, which is lightweight and easy to process, at low cost and efficiently. It is an object of the present invention to provide a method for producing a stone-toned material that can be used.
【０００７】[0007]
【課題を解決するための手段】上記目的を達成するため
に請求項１に記載の発明に係る石材調板材の製造方法で
は、表面形成用の型上に未硬化の熱硬化性樹脂バインダ
ーと石片とを混合して敷均し、その上に未硬化の熱硬化
性組成物と木質材料とを含む混合材をほぼ均等に敷均
し、これら二つの層をその積層方向に加圧するとともに
加熱し一体にして硬化させるものとする。According to a first aspect of the present invention, there is provided a method for manufacturing a plywood material, comprising the steps of: forming an uncured thermosetting resin binder and a stone on a surface forming die; The pieces are mixed and leveled, and the mixed material containing the uncured thermosetting composition and the wood material is spread almost evenly thereon, and the two layers are pressed and heated in the laminating direction. And cured together.
【０００８】また、請求項２に記載の発明に係る石材調
板材の製造方法では上記請求項１に記載の石材調板材の
製造方法において、上記熱硬化性組成物を、アルミナセ
メント並びに無水石膏又は（及び）半水石膏を主成分と
する熱硬化成分とポルトランドセメントを含むセメント
組成物とする。According to a second aspect of the present invention, there is provided a method for manufacturing a stone flooring material according to the first aspect, wherein the thermosetting composition comprises alumina cement and anhydrous gypsum or (And) a cement composition containing a thermosetting component mainly composed of gypsum hemihydrate and Portland cement.
【０００９】上記熱硬化性樹脂バインダーは、例えばア
クリルエマルジョン、エポキシエマルジョン、ポリウレ
タンエマルジョン、シリコンアクリルエマルジョン、フ
ッ素エマルジョン等ガラス転移点が３０〜９０℃のエマ
ルジョン樹脂の単体もしくはそれぞれの複合系エマルジ
ョン等を使用することができる。また、上記熱硬化性組
成物としてセメント組成物を使用する場合にはこのセメ
ント組成物を硬化させる際の温度で硬化するような熱硬
化性樹脂を用いるのが望ましい。As the thermosetting resin binder, for example, an emulsion resin having a glass transition point of 30 to 90 ° C., such as an acrylic emulsion, an epoxy emulsion, a polyurethane emulsion, a silicone acrylic emulsion, a fluorine emulsion, or a complex emulsion of each of them is used. can do. When a cement composition is used as the thermosetting composition, it is desirable to use a thermosetting resin that cures at the temperature at which the cement composition is cured.
【００１０】上記熱硬化性組成物はセメント組成物の他
に、熱硬化性の合成樹脂、天然樹脂等を用いることもで
きる。As the thermosetting composition, a thermosetting synthetic resin, a natural resin or the like can be used in addition to the cement composition.
【００１１】上記表面形成用の型は、この上面に石片を
含む樹脂層が圧接されて石材調の表面を形成するもので
あり、樹脂バインダーがこの型に付着しないように表面
処理が施されたものとするのが望ましい。In the mold for forming a surface, a resin layer containing a piece of stone is pressed onto the upper surface to form a stone-like surface, and a surface treatment is performed so that a resin binder does not adhere to the mold. It is desirable that
【００１２】また、上記型上に供給される熱硬化性樹脂
バインダーと石片とは別々に供給してもよいし、あらか
じめ混合した後供給してもよい。すなわち、天然石等の
石片を１０００〜５０００ｇ／ｍ2 の範囲で散布した
後、上記熱硬化性樹脂バインダーを１０００〜３０００
ｇ／ｍ2 の範囲で別々に散布し敷均してもよいし、上記
石片と熱硬化性樹脂バインダーとが適宜割合で配合され
た混合体を２０００〜１００００ｇ／ｍ2 、好ましくは
４０００〜８０００ｇ／ｍ2 の範囲で一度に散布し敷均
してもよい。Further, the thermosetting resin binder and the stone pieces supplied on the mold may be supplied separately, or may be supplied after being mixed in advance. That is, after the stone pieces such as natural stones are sprayed in the range of 1000 to 5000 g / m 2 , the above-mentioned thermosetting resin binder is dispersed in the range of 1000 to 3000 g / m 2.
g / m 2 , which may be separately sprayed and leveled, or a mixture in which the above-mentioned stone pieces and the thermosetting resin binder are blended at an appropriate ratio is 2,000 to 10,000 g / m 2 , preferably 4,000 to 10,000 g / m 2 . You may spray and spread at once in the range of 8000 g / m 2 .
【００１３】[0013]
【作用】上記のような石材調板材の製造方法では、未硬
化の熱硬化性樹脂バインダーと石片との混合材と、未硬
化の熱硬化組成物と木質材料とを含む混合材とが積層さ
れてこれらの積層方向に加圧されるとともに加熱される
ので、二つの層を有する板状に成型されるとともに熱硬
化性樹脂バインダーと熱硬化性組成物とは同時に短い時
間で硬化して一体となる。硬化した樹脂バインダーと石
片とからなる層は石材調の外観を有し、板材の表面層と
なり、熱硬化性組成物と木質材料とを含む層は、前記表
面層と一体となって基材層を形成する。このように、少
ない工程で、かつ短い製造時間で効率よく石材調の板材
が製造される。In the above-described method for producing a stone board material, a mixture of an uncured thermosetting resin binder and a stone piece and a mixture of an uncured thermosetting composition and a wood material are laminated. Since they are pressed and heated in the direction of lamination, they are molded into a plate having two layers, and the thermosetting resin binder and the thermosetting composition are simultaneously cured in a short time and integrated. Becomes The layer composed of the cured resin binder and the stone pieces has a stone-like appearance, becomes a surface layer of the plate material, and the layer containing the thermosetting composition and the woody material is integrated with the surface layer to form a substrate. Form a layer. In this way, a stone-like plate material can be efficiently manufactured in a small number of steps and in a short manufacturing time.
【００１４】また、上記のようにして製造された石材調
板材は、石材調の外観を持つ表面層に基材層が積層して
形成されていることにより高価な樹脂バインダーや石材
の使用を低減しても、充分な強度を有する板材が得られ
る。さらに基材層は木質材料を含むことにより軽量で加
工が容易となり、表面層も樹脂バインダーで固められて
いるので切断等の加工が容易で釘を打ち付けることもで
きる。Further, the stone-prepared stone material manufactured as described above reduces the use of expensive resin binders and stone materials by forming the base material layer on a surface layer having a stone-like appearance. Even so, a plate having sufficient strength can be obtained. Further, the base material layer is light in weight and easy to work by containing a woody material, and the surface layer is also hardened with a resin binder, so that processing such as cutting is easy and nails can be driven.
【００１５】さらに、木質材料と混合して用いる熱硬化
性組成物を、アルミナセメント並びに無水石膏又は（及
び）半水石膏を主成分とする熱硬化成分とポルトランド
セメントを含むセメント組成物とすると、セメント組成
物は大きな強度を発現するとともに樹脂等に比べて安価
であり、基材層を形成する材料のコストが低減される。Further, when the thermosetting composition used by mixing with the woody material is a cement composition containing a thermosetting component mainly composed of alumina cement and anhydrous gypsum or (and / or gypsum hemihydrate) and Portland cement, The cement composition exhibits high strength and is inexpensive as compared with resin and the like, and the cost of the material for forming the base material layer is reduced.
【００１６】[0016]
【実施例】以下本発明の実施例について詳細に説明す
る。Embodiments of the present invention will be described below in detail.
【００１７】本実施例の石材調板材の製造方法で用いる
材料は次の通りである。The materials used in the method for manufacturing a stone-finished board according to the present embodiment are as follows.
【００１８】板材の表面層を形成する混合材の熱硬化性
樹脂バインダーとしてはアクリルエマルジョンを用い、
石片は御影石の粉砕片を用いる。基材層を形成する熱硬
化性組成物は、アルミナセメント、半水石膏及び消石灰
を主成分とする熱硬化成分と早強ポルトランドセメント
とを含むセメント組成物であり、木質材料は木粉（２０
〜３０メッシュ）及び木片（５〜３０ｍｍ）を用いてい
る。このセメント組成物と木質材料とを含み基材層を形
成する混合材はセメント組成物６８０重量部に対して木
粉及び木片を２８０重量部（固形分）を混合し、水／セ
メント組成物比が０．６５となるように水を加えたもの
である。An acrylic emulsion is used as a thermosetting resin binder of the mixture forming the surface layer of the plate material.
Stone pieces use granite crushed pieces. The thermosetting composition forming the base material layer is a cement composition containing a thermosetting component mainly composed of alumina cement, hemihydrate gypsum and slaked lime, and an early-strength Portland cement.
-30 mesh) and a piece of wood (5-30 mm). The mixture containing the cement composition and the woody material to form the base material layer is obtained by mixing 680 parts by weight of the cement composition with 280 parts by weight of wood powder and wood chips (solid content). Is 0.65.
【００１９】また、上記セメント組成物の配合は次に示
す通りである。The composition of the cement composition is as follows.
【００２０】（セメント組成物の配合） 早強ポルトランドセメント ： ４２１ 重量部 アルミナセメント ： １２６ 重量部 半水石膏 ： ７６ 重量部 消石灰 ： ５１ 重量部 クエン酸ソーダ ： ６ 重量部 図１は、上記のような材料を用いた石材調板材の製造方
法を示す概略工程図である。(Blend of Cement Composition) Early strength Portland cement: 421 parts by weight Alumina cement: 126 parts by weight Gypsum hemihydrate: 76 parts by weight Slaked lime: 51 parts by weight Sodium citrate: 6 parts by weight FIG. It is a schematic process drawing showing the manufacturing method of the stone board material using various materials.
【００２１】（ａ）図に示すように金型３上に上記表面
層を形成する混合材１を６７００ｇ／ｍ2 程度供給し、
ほぼ均等となるように敷均す。この混合材１は樹脂バイ
ンダーと石片とがあらかじめ混合されたものである。一
方、金型３の上面はフッソ樹脂が焼き付けされており、
混合材３の付着を防止するようになっている。(A) As shown in the figure, about 6700 g / m 2 of the mixed material 1 for forming the above-mentioned surface layer is supplied onto the mold 3.
Spread so that it is almost even. This mixed material 1 is a material in which a resin binder and a stone piece are mixed in advance. On the other hand, the upper surface of the mold 3 is baked with fluorine resin,
The mixture 3 is prevented from adhering.
【００２２】次に上記基材層を形成する混合材２を、
（ｂ）図に示すように表面層を形成する混合材１の層の
上に供給して敷均す。Next, the mixed material 2 for forming the base material layer is
(B) As shown in the figure, the mixture is supplied and spread on the layer of the mixture 1 forming the surface layer.
【００２３】このように積層された混合材を（ｃ）図に
示すように金型３とともに加熱加圧機（ホットプレス
機）の加圧体４，４間に差入れ、加圧するとともに加熱
する。このときの加熱温度は９０〜１１０℃程度とし、
圧力は２５Ｋｇ／ｃｍ2 とする。このような状態で２０
分間加熱および加圧した後硬化した成型体を金型３とと
もに取り出し、脱型して養生する。The mixed material thus laminated is inserted between the pressing members 4 and 4 of a heating / pressing machine (hot press machine) together with the mold 3 as shown in FIG. The heating temperature at this time is about 90 to 110 ° C,
The pressure is 25 kg / cm 2 . Under these conditions, 20
After being heated and pressurized for a minute, the cured molded body is taken out together with the mold 3, removed from the mold, and cured.
【００２４】このようにして製造された石材調板材１０
は、図１（ｄ）に示すように石片と樹脂とからなる表面
層１１と、木片および木粉をセメント組成物で固めた基
材層１２とが積層された構造となり、表面層１１は混入
されている石片によって外観が石材に似たものとなる。
また、基材層１２は建材として用いるのに充分な強度と
良好な加工性を有する。The thus-produced stone board 10
Has a structure in which a surface layer 11 made of stone pieces and resin and a base layer 12 obtained by solidifying wood pieces and wood flour with a cement composition as shown in FIG. The appearance of the stones resembles that of stones due to the mixed stone pieces.
Further, the base material layer 12 has sufficient strength and good workability to be used as a building material.
【００２５】なお、上記実施例において、石材は御影石
のほか大理石等様々な種類の石材を用いることができ
る。また、基材層に用いるセメント組成物の配合は適宜
変更することが可能である。In the above embodiment, various types of stones such as marble can be used in addition to granite. Further, the composition of the cement composition used for the base material layer can be appropriately changed.
【００２６】[0026]
【発明の効果】以上説明したように本発明の石材調板材
の製造方法では、未硬化の熱硬化性樹脂バインダーと石
片との混合材と、未硬化の熱硬化組成物と木質材料とを
含む混合材とを積層し、これらの積層方向に加圧すると
ともに加熱するので二つの層を同時に成型および硬化さ
せることができる。As described above, according to the method for manufacturing a stone board material of the present invention, a mixture of an uncured thermosetting resin binder and stone pieces, an uncured thermosetting composition and a wood material are used. The two layers can be molded and cured at the same time because the mixed material is laminated and heated while being pressed and heated in the laminating direction.
【００２７】これにより、石材調の外観を呈する表面層
と充分な強度と加工性を有する基材層とが一体となった
石材調板材を少ない工程で、かつ短い時間で製造するこ
とが可能となる。したがって量産が可能となり製造コス
トの低減も可能となる。Thus, it is possible to manufacture a stone-prepared plate in which a surface layer having a stone-like appearance and a base layer having sufficient strength and workability are integrated in a small number of steps and in a short time. Become. Therefore, mass production is possible and manufacturing cost can be reduced.
【００２８】また、基材層は木質材料を含んでいるの
で、安価かつ軽量で加工が容易な石材調板材とすること
ができる。Further, since the base material layer contains a woody material, it is possible to provide a low-cost, light-weight, easy-to-process stone board material.
【図１】本発明の一実施例である石材調板材の製造方法
を示す概略工程図である。FIG. 1 is a schematic process chart showing a method for manufacturing a stone-plated material according to one embodiment of the present invention.
１ 表面層を形成する混合材 ２ 基材層を形成する混合材 ３ 金型 ４ 加圧加熱機の加圧体 １０ 石材調板材 １１ 表面層 １２ 基材層 DESCRIPTION OF SYMBOLS 1 The mixture material which forms a surface layer 2 The mixture material which forms a base material layer 3 A metal mold 4 The pressurized body of a pressure heating machine 10 Stone board 11 Surface layer 12 Base material layer
───────────────────────────────────────────────────── フロントページの続き (56)参考文献 特開 昭49−2881（ＪＰ，Ａ) 特開 昭50−35213（ＪＰ，Ａ) 特開 平１−285307（ＪＰ，Ａ) 特公 昭49−19696（ＪＰ，Ｂ１) (58)調査した分野(Int.Cl.7，ＤＢ名) B28B 3/00 B32B 19/02 ──────────────────────────────────────────────────続 き Continuation of the front page (56) References JP-A-49-2881 (JP, A) JP-A-50-35213 (JP, A) JP-A-1-285307 (JP, A) 19696 (JP, B1) (58) Field surveyed (Int. Cl. 7 , DB name) B28B 3/00 B32B 19/02
Claims (2)
バインダーと石片とを混合して敷均し、その上に未硬化
の熱硬化性組成物と木質材料とを含む混合材をほぼ均等
に敷均し、これら二つの層をその積層方向に加圧すると
ともに加熱し一体にして硬化させることを特徴とする石
材調板材の製造方法。An uncured thermosetting resin binder and a stone piece are mixed and spread on a surface forming mold, and a mixture containing an uncured thermosetting composition and a wood material is further placed thereon. A method for manufacturing a stone board material, comprising: spreading a material almost evenly; pressing these two layers in the laminating direction, heating and integrally hardening the two layers.
並びに無水石膏又は（及び）半水石膏を主成分とする熱
硬化成分とポルトランドセメントとを含むセメント組成
物であることを特徴とする上記請求項１に記載の石材調
板材の製造方法。2. The thermosetting composition according to claim 1, wherein said thermosetting composition is a cement composition comprising a portland cement and a thermosetting component mainly composed of alumina cement, anhydrous gypsum or (and / or gypsum hemihydrate). The method for producing a stone-finished board according to claim 1.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP4102826A JP3006955B2 (en) | 1992-04-22 | 1992-04-22 | Manufacturing method of stone board |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP4102826A JP3006955B2 (en) | 1992-04-22 | 1992-04-22 | Manufacturing method of stone board |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| JPH05293807A JPH05293807A (en) | 1993-11-09 |
| JP3006955B2 true JP3006955B2 (en) | 2000-02-07 |
Family
ID=14337830
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP4102826A Expired - Fee Related JP3006955B2 (en) | 1992-04-22 | 1992-04-22 | Manufacturing method of stone board |
Country Status (1)
| Country | Link |
|---|---|
| JP (1) | JP3006955B2 (en) |
Families Citing this family (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO2005021254A1 (en) * | 2003-08-28 | 2005-03-10 | Surfaces Techniboard Inc. | Stone-like laminate |
| RU2363585C2 (en) * | 2004-12-17 | 2009-08-10 | Чейл Индастриз Инк. | Artificial marble and method for its production |
-
1992
- 1992-04-22 JP JP4102826A patent/JP3006955B2/en not_active Expired - Fee Related
Also Published As
| Publication number | Publication date |
|---|---|
| JPH05293807A (en) | 1993-11-09 |
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