JP3312743B2 - Architectural decorative panel - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a decorative panel for building which is laid on the surface of a building such as a wall or a floor.

[0002]

2. Description of the Related Art Conventionally, when decorating the surface of a building structure, a decorative panel for building is attached to an outer wall, an inner wall, and / or a floor of the building structure. Natural stone panels such as marble are widely used as such decorative panels for construction.

[0003] A natural stone panel is made by cutting natural stone into predetermined dimensions, and when decorating the surface of a building structure using such a natural stone panel, natural stones of the same color and pattern are combined so as to be continuous as much as possible. ing.

[0004]

However, natural materials such as marble have different appearance characteristics such as color tone and pattern, and the yield becomes extremely poor if natural stones of the same color tone and pattern are widely collected. Invites high prices. In addition, natural stone with a slight scratch on the surface is unusable,
In addition, there is a problem that such scratches are easily made when cutting natural stones.

[0005] On the other hand, there are artificial members such as artificial marble, which resemble natural stone, using a synthetic resin. However, such artificial members not only have a completely different surface appearance from natural stone, but also have a problem that it is impossible to reproduce the natural color tone and pattern of natural stone.

Accordingly, an object of the present invention is to provide an architectural decorative panel capable of reproducing appearance properties substantially equal to those of natural stone with good yield.

[0007]

According to the present invention, in order to achieve the above object, a natural stone is finely crushed and fixed by a binder, so that the appearance is substantially the same as a natural stone cut out as it is. A new attempt is being made to provide equal artificial architectural decorative panels. That is,
TECHNICAL FIELD The present invention relates to a decorative panel for construction including a light-transmitting surface layer, an intermediate layer in which crushed natural stone is fixed by a binder, and a substrate layer serving as a reinforcing layer on the back surface.

[0009] A plurality of types of crushed natural stones can be kneaded with a binder, and these can be mixed so as to draw a predetermined color tone and / or pattern. Crushed stone natural stone, straight <br/> size of less than 1mm than 5 [mu], less 1mm than 4 mm,. 4 to
Of the three types of 10mm mixed <br/> at least two things. Moreover, the decorative panel for construction according to the present invention contains 30 to 95% by weight of crushed natural stone in the intermediate layer.

The surface layer is formed of a gel coat made of a thermoplastic resin or a thermosetting resin, or a light-transmitting ready-made resin plate. In particular, the use of a gel coat made of a thermosetting resin improves the surface protection. In addition, by using a translucent resin plate for the surface layer and forming a natural stone pattern on this resin plate in advance, new patterns and colors are integrated with the crushed stone patterns and colors of the natural stone in the intermediate layer. Can be newly formed. It is preferable that the surface layer is formed in a plurality of times. Further, the substrate layer is in a state of low foaming using a polyurethane resin,
Cured while leaving fine bubbles , specific gravity is 1.25 to 25
It is formed of a foamed resin made of 1.8 g / cm ³ of polyurethane foam . The decorative panel for construction of the present invention preferably has an outer frame integrally fixed to the substrate layer made of such a foamed resin. In the present invention, translucency refers to performance of transmitting light, and is a concept including transparency.

[0011]

According to the present invention, even if natural stones are crushed, the appearance of the natural stones can be reproduced because they are collected and fixed with a binder. Natural stones are used after being crushed, so there is no problem even if the natural stones are scratched and cannot be used in the past, or even if the pattern is uneven, etc. By pulverizing them and mixing them appropriately, the natural appearance characteristics of the natural stone, such as the color tone and pattern of the natural stone, can be reproduced. Further, by adding a desired color, it is possible to produce a color that is not originally available in natural stones, such as purple, and it is possible to create other patterns that are not available in natural stones. In addition, you can also create patterns with glitter. Further, the appearance such as color tone and pattern can be made uniform among a plurality of panels, and a large-area decorative panel for construction can be manufactured. In addition, by using the mold to produce the building panel according to the present invention, a large number of duplicate products can be produced.

As the natural stone that can be used in the present invention, any one can be used, and marble, granite, and cold water stone, which are often used as decorative panels for construction, can be particularly exemplified. These natural stones are pulverized in advance to have a diameter of 5 μm to 10 mm.

The crushed natural stone is fixed by a binder. When mixing crushed stone with binder, diameter is more than 5μ
Less than 1mm, 1mm or more and less than 4mm, 4mm or more 10m
Mix at least 2 types of crushed stones
You. In this way, it becomes possible to reproduce substantially the same appearance as natural stone.

Various binders can be used for the binder for fixing the crushed stone, and examples thereof include unsaturated polyester, polyimide, melamine resin, and tetrafluoroethylene. A polymerization initiator such as benzoyl peroxide and peroxide, and a curing agent are added to the binder, and other known stabilizers (antioxidant, heat stabilizer, light stabilizer)
Should be added.

The added amount of crushed stone in the intermediate layer is 30 to 9
5% by weight der Ru. Crushed amount which greater than the binder amount is reduced lithotripsy fixed you cracks occur in the intermediate layer not sufficient. On the other hand, if the amount of crushed stone is smaller than this, the appearance similar to that of natural stone cannot be reproduced.

In the present invention, since natural stone is used after being crushed, it is possible to crush and use a stone having a defect, a stone having a poor pattern, a cut waste stone, etc. which could not be used conventionally. It greatly contributes to cost reduction.

The intermediate layer having the crushed stone is protected by a surface layer made of a translucent gel coat or a translucent resin plate. These surface layers impart gloss to the panel surface according to the present invention, and allow the color tone and pattern of the stone present in the intermediate layer to be visually recognized through the surface layer. Examples of the resin for gel coating include unsaturated polyester, polyarylester, methacrylic resin, polyethylene terephthalate, and ABS resin. In particular, an unsaturated polyester is preferable. A curing agent, a stabilizer, and a polymerization initiator are added to these resins as in the case of the intermediate layer. The resin plate can be formed of a translucent thermosetting or thermoplastic resin.

The surface layer needs a certain thickness to protect the intermediate layer and to create a deep transparent layer. However, if a gel coat having such a thickness is to be formed at a time, cracks or distortions occur in the surface layer. Therefore, a gel coat is formed by dividing into a plurality of gel coats, and a thick gel coat (layer having a thickness of 0.1 to 0.5) is first formed.
mm) to form a glossy transparent layer and then a relatively thin gel coat (layer thickness 0.1-0.3).
mm) is preferable because it is possible to form a deep, translucent protective surface while preventing the occurrence of cracks and distortion. If the time until the curing of the gel coat is completed is too short, there is a problem of distortion and cracks, and the curing time may be adjusted to a desired range by appropriately adjusting the addition amount of the curing agent. The curing time is preferably from 1 to 25 minutes, and the curing temperature is preferably from 40 to 70 degrees.

In order to shorten the curing time of the resin, for example, U
A V-cured resin or a positive photosensitive polyimide resin can be used as a gel coat material or mixed with another gel coat material. When such a photocurable resin is used, an ultraviolet irradiation device is required. Upon irradiation with ultraviolet rays, polymerization of the resin proceeds by a crosslinking agent contained in the resin. Since the organic solvent remains in the gel coat after the polymerization, it is desirable to completely remove the organic solvent by heating the resin to 300 to 35 degrees to completely cure the resin (the heat resistance temperature of the resin). Is lower than this, decrease the heating temperature.) Polishing the gel coat layer and / or the surface layer, which is a resin plate, with an abrasive having abrasive grains of $ 500 to 2,000 (JIS) to provide a glossy translucent building panel. can do.

The substrate layer serves as a reinforcing layer on the back surface of the building panel according to the present invention, and supports the intermediate layer protected by the surface layer. Such a substrate layer,
It is excellent in stress dispersion performance when a load is applied to the surface of the structure according to the present invention, and is also excellent in heat insulation. And cured while leaving fine air bubbles, and having a specific gravity of 1.25 to 1.8 g / cm ³ .
Form from foam .

The decorative decorative panel according to the present invention is characterized in that a resin layer is applied to a mold for manufacturing the decorative decorative panel, and then the resin is cured to form a surface layer made of a translucent gel coat. Formed, crushed natural stones are kneaded with a binder and made into a semi-fluid state, and then supplied into a mold, and then the binder is hardened to form an intermediate layer in which the natural stone crushed stones are fixed following the gel coat layer. In addition, a resin serving as a reinforcing material is supplied into a mold to form a substrate layer subsequent to the intermediate layer.
Also, instead of forming a gel coat, a thickness of 0.3 to 1
mm is placed in a mold in advance as a surface layer, and a semi-fluid material obtained by kneading crushed natural stone with a binder is supplied thereon. A decorative panel can also be manufactured.

By sequentially supplying the resin material for forming the surface layer, the intermediate layer, and the substrate layer into the mold, the building panel can be manufactured in a state where these layers are integrated. For this reason, the exterior shape of the decorative panel for building is equal to the shape of the mold, and by appropriately designing the shape of the mold, a curved or three-dimensional panel which has conventionally been difficult to cut from a rough stone. However, it can be easily created. Therefore, the decorative panel for construction according to the present invention can be stuck not only to a flat wall and floor, but also to a curved wall and floor surface. In addition, by using a large mold, a large-area panel can be made. Further, by changing the mold, the panel itself according to the present invention can be independently formed by itself such as a bathtub, furniture, and a table. Of goods.

[0023]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment of the present invention will be described below with reference to the accompanying drawings. FIG. 1 shows an embodiment of a decorative panel for construction. The decorative panel for construction shown in FIG. 1 has a surface layer 2 made of a transparent gel coat 10 from the surface side and an intermediate layer 4 in which crushed stones 14 of natural stone are fixed by a binder 16.
And a substrate layer 6 made of a foamed resin 18. Further, a backup layer 20 made of, for example, a glass fiber wool compression plate or a gypsum board such as a noncombustible material or a flame retardant material is provided on the entire back surface of the substrate layer 6. I have. Then, bolts 21 are used as fixing parts when fixing the decorative panel for construction to a wall, a floor or the like.
Are integrally embedded in the substrate layer. The layers are integrated by bonding to each other at the interface with the other layers. The natural stone pattern in the mid layer 4 can be seen through from the surface layer 2 of the decorative panel for building. When attaching such a building decorative panel to a building structure such as a wall or a floor,
A plurality of the decorative decorative panels are used in combination according to the shape of the original wall surface.

FIG. 2 shows another embodiment of the decorative panel for construction, in which the surface layer 2 wraps around the side of the decorative panel for construction to protect the side surface of the decorative panel for construction and also the intermediate layer 4. Also wrap around the side surface of the decorative panel for construction and cover the side surface of the substrate layer 6. According to this embodiment, the architectural decorative panel of FIG.
While the foamed resin 18 of the substrate layer 6 is observed,
In the decorative panel for construction of this embodiment, the natural stone pattern in the intermediate layer 4 can be observed not only from the surface but also from the side via the gel coat 10, so that the decorative effect of the decorative panel for construction can be significantly improved. As in this embodiment, hooks 22 can be embedded instead of bolts as fixing parts for fixing the decorative panel for building to a wall, a floor, or the like, or both may be embedded.

Next, the manufacture of the decorative panel for construction according to the present invention will be described. FIG. 3 shows a first step of manufacturing a decorative panel for a building. Architectural decorative panels are obtained by sequentially supplying resins that form a surface layer, an intermediate layer, and a substrate layer into a mold, but the mold used here is composed of an upper mold and a lower mold. And 30 indicates a lower mold. The lower mold 30 is designed in accordance with the shape of a target decorative panel for construction, and is provided therein with a pipe 32 to which a heat source such as hot water or steam is supplied. Such a conduit 32 is
As shown in the rear view of the lower mold in FIG. 4, the lower mold 30 is formed to meander over a wide area, and an inlet pipe 34 and an outlet pipe 36 of hot water are connected to each end.

When forming the surface layer of the decorative panel for building, first, a gel coat material to be the surface layer is prepared. As the gel coat material, a resin composed of 95% by weight of an equimolar mixture of terephthalic acid and ethylene glycol to be polymerized into an unsaturated polyester and 5% by weight of a curing agent, methyl ethyl ketone peroxide, and a stabilizer such as an organic cobalt agent. A paste in which an organic solvent (styrene monomer) is added in an appropriate amount to the composition is used. The gel coat material is poured into the lower mold 30 and spread thinly with a spatula or the like so as to have a thickness of 0.1 to 0.5 mm to a uniform thickness. Note that a gel coat material may be uniformly sprayed on the inner wall of the lower mold 30 instead of the spatula coating.

After the gel coat material is applied, a heat medium such as hot water is supplied to the pipe 32, and the lower mold is heated to a temperature of 35 to 75 ° C.
Hold for ~ 15 minutes until the gel coat material is dry to the touch where it does not completely solidify. By this heating, the gel coat is thermally cured to form the front side of the surface layer.
Note that an electric heater may be provided instead of providing a pipe through which hot water or the like is circulated in the lower mold, or the mold may be placed in a heating furnace without providing these heaters.

Next, the same gel coat material is applied uniformly on the gel coat in a dry state to the touch so that the film thickness becomes 1.5 to 0.8 mm. At this time, since the hot water has just been introduced into the pipeline in the lower mold, the gel coat material applied for the second time can be dried by the heat storage of the mold. The surface layer 2 made of the translucent gel coat 10 is formed by the gel coat material applied twice.

Next, the process proceeds to the second step shown in FIG. 5, and when the gel coat applied for the second time is dry to the touch, the paste obtained by kneading the crushed natural stone 14 together with the binder 16 is applied to the surface layer 2. Paint with a spatula or roll from above. When coating such a paste, the film thickness is 1
The coating was uniformly performed so as to have a thickness of about 10 to 10 mm. After the coating, warm water was circulated through the pipe 32 of the lower mold to maintain the mold temperature at 65 to 85 ° C. and held for about 5 to 20 minutes.

The natural stone is pulverized in advance using a known crusher, and a crushed stone having a uniform particle size is selected using a sieve.
The crushed stone remaining on the sieve is crushed again. Crushed stones with a relatively large particle size (1 to 4 mm in diameter), fine particles (30 to 80 μ in diameter), and finer particles (5 to 30 μ in diameter) are mixed in a weight ratio of 2: 4: 4. Then, the mixed crushed stone is thoroughly mixed with 15 to 27% by weight of the same unsaturated polyester as the gel coat and 2 to 4% by weight of a curing agent, a stabilizer and a polymerization initiator, and the mixture is used in this step. The paste was used. At this time, marble (black) and granite (brown) having different colors were separately ground to prepare respective pastes, and the two pastes were mixed so as to form a fixed pattern. Note that the crushed stone fixed to the intermediate layer is also bitten into the gel coat, so that it is more firmly fixed.

Next, the process proceeds to the third step in FIG. In the step shown in FIG. 6, the lower mold 30 is covered with the upper mold 31, and the lower side of the intermediate body of the decorative panel for building composed of the surface layer 2 and the intermediate layer 4 inside the lower mold 30. This is a step of forming the substrate layer 6. In this embodiment, a low foaming polyurethane resin is used for the substrate layer, and such a foaming polyurethane resin is obtained by reaction injection molding. In FIG. 6, 40 is a main agent supply line for isocyanate such as TDI or MDI, 42 is a secondary agent supply line for polyol or the like,
44 is an organic tin-based compound such as Dibtyltindilaurate, Triethy
This shows a line for supplying an organic catalyst such as lenediamine and the like and a second auxiliary agent such as water and silicone. Reference numeral 46 denotes a mixing device for mixing the main agent, the auxiliary agent, and the second auxiliary agent, and an injection hole 48 for injecting these agents is formed at the center of the mixing device. A piston 50 slides in the injection hole 48, and the piston 50 is advanced and retracted in the injection hole by hydraulic pressure by a cylinder 52.
The tip of the supply line of each of the medicines is exposed to the injection hole 48.

Each of the medicine supply lines is connected to a pressure applying / discharging device (not shown), and the medicine is delivered under pressure to each of the medicine supply lines, and the medicine is ejected into the injection hole 48 from the tip of the line. When the medicine is injected, the upper die 31 is pressed against the lower die 30 by a pressing device (not shown) so that the inside is closed. The foaming properties of the foamed resin used in this example are of a type called rigid integral skin polyurethane foam, and the specific gravity after foaming is 1.25 to 1.8 g.
/ Cm ³ , a cream time of 8 to 15 seconds, and a tack free time of 25 to 40 seconds. In addition, 60, 62,
Numeral 64 denotes flow meters for the respective drug supply lines, and the flow meters adjust the mixing ratio of the drugs supplied from the respective lines.

Before the raw material is injected, the upper die 31 and the lower die 30
Is pre-pressurized. The pressure at this time is 3 kg / cm ² . Next, at the same time when the discharger is operated, the lower end of the piston 50 is raised from the position H to the position L. When the lower end of the piston is at the H position, the tip of each line is closed by the piston and the medicine is not discharged into the injection hole 48. However, when the lower end of the piston is at the L position, the tip of each line is opened and each of the lines is opened. The medicine is ejected between the upper mold and the lower mold via the injection hole 48. The jet pressure at this time is 70 to 120
kg / cm ² . Each raw material jetted at a high pressure and high speed from the mixing device is subjected to a mixing and stirring action under a turbulent flow due to a pressure drop after the jetting. The mixed raw materials immediately react and accumulate in the mold. When the ejection of the predetermined amount is completed, the piston is lowered so that the lower end of the piston is at the H position, and the ejection of the medicine is stopped. Immediately thereafter, the pressurizing device is operated to increase the pressure applied to the mold to 12 kg / cm ² , so that the gap between the upper mold 31 and the lower mold 30 is eliminated. As a result, the substrate layer 6 integrated with the intermediate layer 4 can be formed. In addition, as shown in FIG. 7, it is desirable to form a notch 70 groove for air release and gas release on the mating surface of the lower die 30 with the upper die. With such a configuration, a uniform and strong foam layer can be formed.

The polyurethane resin, which is a raw material that fills the space of the mold, undergoes a urethane reaction, and the outer periphery of the mold is fixed, and the central core is low foamed and solidified while leaving fine bubbles. The foamed resin covers the back surface of the intermediate layer to which the crushed stone is fixed when it is still in a gel state immediately before the foaming, and integrates with the intermediate layer by utilizing the action of solidifying the foamed resin and simultaneously performing strong adhesive curing, The back surface side of the intermediate layer is buried and fixed in the polyurethane resin. The internal temperature during the foam solidification is about 150 ° C. Immediately before the contraction after solidification starts, the pressurizing device is operated, and the upper mold 31 is moved to the lower mold 3.
Separate from 0 slightly. At this time, the applied pressure of the pressurizing device is 5
kg / cm ² . Thereby, the internal pressure and gas pressure due to the internal solidification and foaming reaction are easily released to the atmosphere. Next, the architectural decorative panel as a product is removed from the lower mold. 99% of demolished building decorative panels
Although it is a quality that can be used as a product as it is, after cleaning with air for a time, the edges are slightly finished and finished.

The manufacturing method when polyester is used as the material of the substrate layer will be schematically described. The polyester, which is liquid under pressure, is used as the intermediate 41 of the decorative panel for building.
Is injected into the mold in which is arranged. Here, a polyester resin is used as a main agent, and a fiberglass chop or a curing agent is used as an auxiliary agent, and is injected into a mold together with a stabilizer and a catalyst. Then, at the same time as the polyester resin is solidified, the polyester resin is fixed to the intermediate layer.

As shown in FIGS. 1 and 2, when the backup layer is to be fixed to the gypsum plate on the back side of the substrate layer, the backing material relating to the inner surface of the upper mold is provided in advance. By injecting the foamed resin, the foamed resin and the backup are fixed in the process of foaming and solidifying the foamed resin. Similarly, when attaching an outer frame made of aluminum extruded material, steel or stainless steel pipe, hard extruded vinyl material, etc. to the back and outer surfaces of the decorative panel for building, the outer frame was similarly attached to the upper mold. By injecting the post-foam resin, the foam layer and the outer frame can be integrated. Further, when embedding bolts or the like in the substrate layer, it is preferable to arrange the bolts or the like upright with respect to the intermediate layer and to inject foamed resin in this state.

Since the decorative panel for building according to the present invention can be prepared by supplying resin into a mold, it is possible to prepare decorative panels of various shapes by changing the shape of the mold. it can. For example, by making the inside of the mold a semicircular shape in FIG. 8 and a corrugated shape in FIG. 9, it is possible to produce a decorative panel for building having a shape equal to such an internal shape. FIG. 10 shows a perspective view of an architectural decorative panel made using a mold having a corrugated interior.

Since the decorative panel for construction according to the present invention is prepared by using the mold as described above, the decorative panel for construction is used as an article having an independent use, for example, a bathtub as shown in FIG. Can be Such an article is a very high value-added article in which a natural stone pattern can be visually recognized from the surface.

Incidentally, a coating of a UV-curable resin or a positive photosensitive polyimide resin having a predetermined thickness, for example, 0.2 to 0.5 mm, is applied on the surface layer made of the gel coat to further increase the surface hardness and to scratch the surface. It is more preferable to make it difficult. In addition, by changing the properties of the mold surface, the surface of the gel coat can be made relatively rough instead of being smooth.

[0040]

As described above, according to the present invention, natural stone is finely crushed and crushed stone is fixed with a binder, so that appearance characteristics almost equal to natural stone can be reproduced with good yield. Panels can be provided.

[Brief description of the drawings]

FIG. 1 is a cross-sectional view showing one embodiment of a decorative panel for construction according to the present invention.

FIG. 2 is a sectional view showing a second embodiment of the decorative panel for construction.

FIG. 3 is a cross-sectional view of the decorative panel for building showing a first step of manufacturing the decorative panel for building;

FIG. 4 is a rear view of a mold for manufacturing a decorative panel for building.

FIG. 5 is a sectional view of the decorative panel for building showing a second step of manufacturing the decorative panel for building;

FIG. 6 is a configuration diagram of a foaming resin injection system showing a third step of manufacturing a decorative panel for building.

FIG. 7 is a perspective view of a lower mold.

FIG. 8 is a sectional view showing another example of a mold for manufacturing a decorative panel for construction according to the present invention.

FIG. 9 is a sectional view showing still another example of a mold for manufacturing a decorative panel for construction according to the present invention.

FIG. 10 is a cross-sectional perspective view of an architectural decorative panel formed in a corrugated shape.

FIG. 11 is a cross-sectional perspective view of a bathtub made of a decorative panel for construction according to the present invention.

[Description of Signs] 2 Surface layer 4 Intermediate layer 6 Substrate layer 10 Gel coat 14 Natural stone crushed stone 16 Binder 18 Foam resin 20 Backup layer 30 Lower mold 31 Upper mold

──────────────────────────────────────────────────続 き Continuation of front page (56) References JP-A-3-228959 (JP, A) JP-A-2-133352 (JP, A) JP-A-51-514 (JP, A) JP-A-3- 288627 (JP, A) Japanese Utility Model Hei 2-20612 (JP, U) (58) Field surveyed (Int. Cl. ⁷ , DB name) E04F 13/08 A B32B 5/16 B44C 5/06 J E04F 13 / 18 A

Claims (2)

(57) [Claims] An architectural decorative panel comprising: a light-transmitting surface layer; an intermediate layer in which crushed natural stone is finely crushed and fixed with a binder; and a substrate layer serving as a reinforcing layer on the back surface. The crushed natural stone has a diameter of 5μ or more and less than 1mm, 1
The mixture is a mixture of at least two of three types of not less than 4 mm and not more than 4 mm and not less than 4 mm and not more than 10 mm, and is contained in the intermediate layer in an amount of 30 to 95% by weight. The foamed resin was cured using polyurethane resin in a state of low foaming while leaving fine bubbles , and the specific gravity was 1.25 to 1.8 g / cm ³ .
An architectural decorative panel characterized by being a polyurethane foam . 2. The architectural decorative panel according to claim 1, having an outer frame integrally fixed to said substrate layer.