JP3251354B2 - High density artificial stone and its manufacturing method - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a cylindrical high-density artificial stone and a method for producing the same. More specifically, the present invention relates to a high-density artificial stone having a marble-like excellent texture and a method for producing the same, and includes wall materials, floor materials,
The present invention provides artificial stones useful as other building materials, civil engineering materials, stone pillars, and the like.

[0002]

2. Description of the Related Art It has been known that a natural stone is crushed into an appropriate size, mixed with calcium carbonate and a resin, and then hardened to form an artificial stone. That is, for example, Japanese Patent Application Laid-Open No. 61-101443 discloses a method of obtaining a lump that the obtained artificial stone can withstand cutting, and mixing raw stone powder, resin and the like under reduced pressure. It is described that this is poured into a mold, taken out and subjected to cutting.

Further, Japanese Patent Publication No. 53-24447 discloses that when artificial stone is manufactured by using natural stone powder and synthetic resin, raw materials are used at a predetermined mixing ratio, The necessity of applying sufficient pressure after insertion is stated. Also, as pointed out in these known examples, the problem with artificial stones obtained by such a method is that molding using a mold frame causes bubbles to remain inside the molded body. And that fluidity must be ensured for pouring the resin and stones into the formwork.

Therefore, for example, Japanese Patent Publication No. 53-24447.
In the publication, fluidization is achieved by increasing the amount of the resin component, and the generation of bubbles can be prevented by ensuring fluidization. However, on the other hand, increasing the resin component to prevent the generation of bubbles or to secure the fluidity for feeding into the mold is completed even if it is useful for securing the fluidity and preventing the generation of bubbles. The nature of the artificial stone has an adverse effect.

[0005] In other words, the use of a large amount of the resin component leads to the conversion of the product into a resin, and the obtained product merely has powder particles of natural stone in the resin. It has become close to. Therefore, although it is called artificial stone, what is obtained is a resin product that looks like stone. In addition, when using a mold, pressurizing the mold in a sealed state means that the generated foam is only crushed and cannot be essentially escaped, and part of it remains on the surface or inside of the product and the surface It loses aesthetics and degrades its physical properties.

[0006] In order to solve the above-mentioned drawbacks of the conventional artificial stones and to use a powdered material such as a natural stone as a material,
The resulting product has high density and physical properties close to those of natural stones. The composition of a new artificial stone that allows the metal to have an arbitrary shape such as a plate shape or a rod shape, and a production method thereof have been energetically studied.

However, the fact is that practical artificial stones have not always been realized so far. The reason for this is that, together with the material composition, there is a great problem in the method of processing the surface properties of the product, which is closely related to this. That said, even in the case of natural stone, in order to give an excellent texture, the required irregularities are formed on the surface,
This is also because in the artificial stone using a resin, the unevenness causes the texture to be impaired.

[0008] More specifically, conventionally, as a method of giving irregularities to the surface of a natural stone, a jet burner method for causing interface separation due to a difference in thermal expansion of a mineral, or an impact of an iron ball or a chisel is used. Tataki finishing or the like that physically destroys the surface is mainly used, and in a cement artificial stone (Terrazzo), the Tataki finishing method is mainly used.

However, in the case of resin-based (acrylic, unsaturated polyester, etc.) artificial stones, the jet burner method cannot be used. However, there is a major drawback in that even if the coloring is carried out by mixing them, the split surface is whitened and the coloring itself becomes meaningless. For this reason, it is a fact that there is no artificial stone that is a resin artificial stone having an uneven surface, has a good texture and texture, and embodies excellent marble-like quality.

[0010] In addition, the resin
Some products are made by casting or pressing a mixture of aggregates and fillers, and then cured.They are all covered with a resin film, and have the same abrasion and design characteristics as resin products. I have. The present invention has been made in view of the circumstances as described above, and gives the texture of natural stone, and uses less expensive pure stone and recovered fine powder, other inorganic raw materials, and has surface irregularities, Another object of the present invention is to provide a new high-quality artificial stone that can be easily used for various purposes and a method for producing the same.

[0011]

DISCLOSURE OF THE INVENTION The present invention has been made to solve the above problems, and comprises an inorganic fine particle component having a size of 10 to 70 mesh and an inorganic fine particle component having a size of 100 mesh or more. The weight ratio is 0.5: 1 to 5: 1,
A high-density artificial stone characterized in that the sum is 85% by weight or more of the product, the resin component has a mixed composition of 15% by weight or less, and the fine-grained component is exposed on the surface. provide.

[0012] The present invention also has a preferred embodiment of an artificial stone in which the resin component is removed by softening or melting at a surface portion and a fine-grained component is exposed. Further, according to the present invention, the weight ratio of the inorganic fine particle component having a size of 10 to 70 mesh to the inorganic fine particle component having a size of 100 mesh or more is 0.5: 1 to 5: 1, and the sum is a product. Is 85% by weight or more and the resin component is 15% by weight.
Weight% or less of the mixed composition is poured into a mold and molded.
A method for producing a high-density artificial stone, characterized in that the resin component on the surface is treated with an organic solvent to soften or melt and removed, or the fine-grained component is exposed to the surface by mechanical removal. Is also provided.

Therefore, the present invention will be described in more detail below. First, the raw materials constituting the artificial stone of the present invention are roughly classified into three components. One is 10-70 as the main component
This is a fine-grained component having a mesh size, and an appropriate fine-grained component selected from natural stone, ceramics, glass, metal and the like is used. Some of these small pieces may be mixed in them.

A fine particle component having a size of 100 mesh or more is used together with the fine particle component. Examples of the fine particle component include various natural or artificial fine particle components. Calcium carbonate, aluminum oxide and the like are easy-to-obtain fine-grained components. The third component is a resin component. The resin component can be selected from a wide range of thermosetting ones.

For example, acrylic resin, unsaturated polyester resin and the like are exemplified. Fine-grained components such as natural stones function as major factors in the appearance and physical properties of the resulting artificial stone. In particular, by exposing a part thereof, it becomes a main factor of the appearance color and pattern in combination with other components. The fine-grained component is considerably finer than the 100-grain level compared to the fine-grained component. The fine-grained component is positioned so as to penetrate between the individual grains of the fine-grained component and fill the space between the grains. It contributes to obtaining properties such as hardness and flexibility. The fine particle component and the fine particle component are in a weight ratio of 0.5: 1.
５5: 1 is preferred.

In addition, the resin component is a component which forms fine particles, such as natural stone, which is a component forming the above-mentioned skeleton, and fine particles.
It has a function of wrapping these and contributing to the whole and giving elasticity or tensile strength to the product when the artificial stone is completed. In the present invention, the composition ratio of these components is important. Particularly important is the composition ratio between the resin component and other components. The high density means that the fine and fine components contained in the product are present at a high density, and the degree is, for example, higher than that of the conventional artificial stone having a density of 2 g / cm ³ or more. Is out of range.

That is, as the composition ratio of fine-grained components such as natural stones as a skeleton component in a product increases, the composition becomes closer to natural stones. However, when the composition ratio is too large, the composition does not solidify and cannot be used as a product. In addition, the physical properties of the resulting product are poor and cannot be used in normal usage. Further, in addition to inconveniences such as not hardening even when a large amount of fine particles are used, the resulting material is dull and hard to be called stone.

Accordingly, the proportion of the fine-grained component and the fine-grained component used is limited. That is, the weight ratio must be 85% or more, and preferably 90% or more. If it exceeds 98%, the product becomes brittle, and only those which are difficult to use can be obtained. On the other hand, if it is less than 85%, the product is too soft to obtain stone-like properties, and the range of use is the same as that of the resin plate.

This means that the components other than the fine and fine components such as natural stones, that is, the resin component, must not be present in the product at most in a weight ratio of more than 15%. If the resin component exceeds about 15%, the product becomes plastic, and the artificial stone is no longer just an apparent name. Also, reducing the resin component may increase the tendency of the product to be stone, but the product becomes brittle and unsuitable for use. In reality, it has conventionally been difficult to reduce the content of components such as resin to 10% or less.

The fine particle component has a size of 10 to 70 mesh as described above, but it is preferable to use only the same size component except for special cases. For example, it is conceivable to change the size of fine grains depending on the presence or absence of color when it is desired to add a color to the top or bottom using one with and without a color. The use of large quantities with differences should not be used as it will degrade the strength of the product.

As described above, the size of the particles of the fine component must be able to sufficiently enter between the particles of the fine component. Therefore, those having a size close to the size of the particles of the fine component are not preferred, and those having a size of about 150 to 250 mesh are preferred. Further, what is important in the high-density artificial stone of the present invention is that, except for special cases, it is desirable that these material compositions are uniformly dispersed in any part of the product.

The surface constituting the exterior of the product may be polished. That is, it is preferable that at least a part of the surface has the fine grain component exposed. Polishing is a practical and convenient method for exposing the surface of the dense texture of high-density artificial stone. It should be noted that a part of the surface of the product may be polished to expose fine-grained components, and a difference between the surface and the other part of the same surface may be used as a pattern.

In the case of obtaining artificial stones, it is important to determine what natural stones are targeted. Marble is a popular target because it is difficult to obtain natural marble and its color and luster are beautiful. In this case, the color and luster are important themes that determine the value of marble. In natural marble, there are many types of colors, from completely black to white or red, and the degree is different even for the same color.

Therefore, when giving a color corresponding to these,
For example, in order to obtain a black product, it is only necessary to use a black material such as natural stone or the like, but to obtain a product with an intermediate color,
Difficulty in reproducibility. Giving the unique luster of marble, even with the addition of color, required considerable effort and was sometimes difficult. In particular, it was difficult to give gloss when a color was given using a dye or pigment.

On the other hand, in the present invention, when a glossy material such as marble is to be obtained, fine particles obtained by pulverizing quartz-based natural stone are used as fine particle components. Fine particles obtained by grinding quartz-based natural stone have a unique smooth surface because the raw material is quartz-based. They are often colorless and transparent. They are not very strong when they have colors, and they often have some transparency even when they are not transparent.

When the raw materials selected in this way are used, the color of the obtained product is mainly the color of the resin. Moreover, the color can be seen to have a luster due to the presence of the fine quartz-based component. For example, when a polyester-based unsaturated resin is used as the resin, the color of the resin is generally white with a slightly yellow tint, and the resulting product is glossy milky white, which is very similar to natural milky white marble. A product with a different color tone can be obtained.

When a color is added to a product by adding a pigment or the like to a resin component, a product having a uniform color and a unique color tone can be obtained by using a fine-grained component as a quartz-based component. When adding color to a product, the fine-grained component obtained by crushing quartz-based natural stone is used as it is without any processing for color, and in addition to this, a granular component of approximately the same size as the fine-grained component is used as a color component. Can be used in combination with a colored material to give a color to the product.

At this time, if the mixing ratio between the quartz fine-grained component which has not been processed for the color and the colored one is kept constant, a product having a constant color tone can be obtained. In this case, the reproducibility of the color is much easier than the conventional method of coloring the resin side or using a pigment or the like, there is no discoloration, and the gloss is accurately reproduced. An excellent product is obtained as compared with the conventional coloring method.

Even when a special color is given by using a plurality of kinds of colored fine-grained components, the color adjustment by adding a quartz-based fine-grained component that has not been processed for the color has an extremely excellent effect. Things. Naturally seeking colored fine-grained ingredients is a good method, but the amount is limited,
Colors are limited.

Therefore, it is effective to apply a glaze for coloring ceramics or the like to a natural powder and bake it to obtain a powder of a desired color and use it as a fine particle component. By using this method, not only can the color of the colored body be assured, but also the color can be widely selected. Granular powder of quartz-based natural stone used as the fine-grained component is used as the fine powder, and glaze is applied and baked on it. There is no concern about the reproducibility of the color, and the reproduced color is not only the color itself, but also the gloss and the color tone, and is completely reproduced.

The high-density artificial stone of the present invention, which also has such excellent color characteristics, has a plate-like, rod-like,
It can be arbitrary such as cylindrical. A molding method for this purpose is also variously selected, and for example, cast molding, compression molding and the like are appropriately considered. In any case, what is important as the production method of the present invention is that the mold used is not a closed mold. That is, the open portion must clearly be part of the total surface area.

For example, when obtaining a rectangular tubular article, it is preferable to use a mold in which the portion forming the edge of the plate inside the mold is open, with the open side higher than the other side. In some cases, the narrow side portion may be semi-opened in addition to the upper portion, that is, the mesh may be formed in a mesh shape so that, for example, the fine-grained component hardly flows out. The size of the part to open is
It may be several percent or less of the entire external area of the internal volume of the mold.

When such a mold is injected with a fluid state in which a resin component, a fine component and a fine component are uniformly mixed, it is necessary to reduce the internal volume of the mold after the injection. It is. For example, when the inside of the mold is flat, the flat plate portion of the mold is brought closer to reduce its thickness. Due to the reduction of the internal volume, the resin component comes out from the inside, gathers at the open part of the mold, and overflows from the open part of the mold. Alternatively, after the injection, the resin component on the upper side flows out by pushing up the bottom part to reduce the internal volume.

That is, since the fine-grained component and the fine-grained component have an apparently higher specific gravity than the resin component, they begin to sink below when injected into the mold. This subsidence occurs quickly because of the large difference in specific gravity. Therefore, when the internal volume is reduced, only the light resin component is pushed outward and moves,
Gather to open areas. Therefore, if the internal volume is previously set to a predetermined value and then the predetermined volume is reduced, a controlled amount of the resin component can be taken out. Therefore, the resin component participating in the solidification is smaller than the amount of the resin component at the time of the injection, and the ratio of the amount of the resin contained in the product can be made smaller than that at the time of the injection.

In the present invention, the surface of the compact after molding may be processed so that the fine-grained component is exposed on the surface. As a method for this, a method for selectively removing a resin component is employed. That is, the surface portion can be treated with an organic solvent to remove or soften or melt the resin component.

The organic solvent used in this case may be selected according to the resin component used. Examples thereof include halogenated hydrocarbons such as ethylene chloride, methylene chloride and chloroform; acetic anhydride, ethyl acetate, and butyl acetate. Examples thereof include carboxylic acids and their ester compounds, acetone, tetrahydrofuran, DMF, DMSO and the like. The molded body can be immersed in these organic solvents or sprayed or flowed down with these organic solvents to remove the softened or melted resin component from the surface to form surface irregularities.

Alternatively, the irregularities may be formed by scraping the resin component having low hardness from the surface with a wire brush, cutting means, or the like. By doing so, an artificial stone having an excellent texture and texture can be manufactured.
Hereinafter, examples will be described. Of course, the present invention is not limited by the following embodiments.

[0038]

EXAMPLE 1 9% by weight of a quartz natural stone having a particle size of 10 to 25 mesh and a calcium carbonate having a mesh size of 230 so as to be 90% by weight of the total weight of the composition at an important ratio of 2: 1. %
Was uniformly mixed with the polymethyl methacrylic resin and 1% by weight of a curing agent to form a mortar.

This composition was charged into a mold, and the thickness was about 1
It was formed into a 5 mm plate. Next, the plate was immersed in a mixed solvent of methylene chloride and ethylene chloride to soften the surface, remove the resin component, and expose the fine particle component. The resulting artificial stone had a completely marble-like milky white color and luster, had no air bubbles inside or on the surface, and had a uniform composition.

The obtained artificial stone had a specific gravity of 2.30, a tensile strength of 122 kg / cm ² , a compressive strength of 605 kg / cm ² , and a bending strength of 640 kg / cm ² , which was close to natural marble. Fine quartz particles were exposed on the surface. When the obtained product was used as a wall plate of a building, a beautiful marble wall having a deep depth could be obtained. Example 2 In Example 1, the sum of the fine particle component and the fine particle component was 93%, and the resin component was softened using a mixed solvent of glacial acetic acid and ethyl acetate, and removed by wire brush treatment.

A high-quality artificial stone was obtained in the same manner as in Example 1. Tensile strength 130 kg / cm ² , compressive strength 60
It had characteristics of 5 kg / cm ² and bending strength of 660 kg / cm ² , and had a marble-like deep and excellent surface.

[0042]

The present invention provides a high-density artificial stone containing a granular material such as a high-density natural stone and a method for producing the same, which have not been obtained before. It is possible to obtain a uniform product which is close to that of natural products and which is difficult to obtain for natural products. Moreover, such excellent products can be manufactured without using specially expensive equipment.

In particular, the high-density artificial stone of the present invention is suitable for obtaining marble-like stones, and can be used in the same manner as natural stones. The product has the same color tone, particularly gloss, as polished from natural stone, and can be used as a wall material, a floor material, a pillar, and the like as a deep luxury product more widely than a natural product.

Conventionally, artificial marble, which was merely apparent, can be provided that is substantially inferior to natural ones, is easier to use, and has artificial advantages.

Claims (3)

(57) [Claims] The weight ratio of the inorganic fine particle component having a size of 10 to 70 mesh to the inorganic fine particle component having a size of 100 mesh or more is 0.5: 1 to 5: 1, and the sum is 85% by weight of the product.
A high-density artificial stone as described above, wherein the resin component has a mixed composition of 15% by weight or less, and the fine-grained component is exposed on the surface. 2. The artificial stone according to claim 1, wherein the resin component is removed by softening or melting at the surface portion, and the fine-grained component is exposed. 3. The weight ratio of the inorganic fine particle component having a size of 10 to 70 mesh to the inorganic fine particle component having a size of 100 mesh or more is 0.5: 1 to 5: 1, and the sum is 85% by weight of the product.
A mixed composition containing 15% by weight or less of the above-mentioned resin component is put into a molding die and molded, and the resin component on the surface is treated with an organic solvent to be softened or melted, or removed. Alternatively, a method for producing a high-density artificial stone, characterized in that the fine-grained component is exposed to the surface by mechanical removal.