JP3398123B2 - Natural stone-like decorative molded article and method for producing the same - Google Patents

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a natural stone tone decorative molded product having a natural stone tone appearance and a method for producing the same.

[0002]

2. Description of the Related Art Conventionally, natural stone-like artificial marble has been known as a decorative molded product used for bathtubs, kitchen counters and the like. This artificial marble is manufactured by using a polymerizable resin solution prepared by dissolving an acrylic resin such as polyethylmethacrylate in an acrylic acid ester monomer such as methylmethacrylate, an inorganic filler such as aluminum hydroxide, and decorative particles or natural ores. Also, a method is used in which a colored product (cold stone, car, etc.) is blended, and this is cured and molded to give a natural stone tone pattern.

As the decorating particles, for example, the decorating particles disclosed in JP-A-10-217700 are used. The particles for decoration are particles for decoration, which are obtained by crushing a cured product obtained by curing an uncured liquid curable resin and have different color tones, while granulating the particles in a particle shape while maintaining the particle form. It is produced by binding particles with a binder resin.

[0004]

However, in this method for producing artificial marble, the production cost of the decorative particles themselves produced by pulverizing the cured product of the uncured liquid curable resin increases, and There is a problem that the decorative particles themselves tend to be monotonous in color, and it is difficult to obtain a natural stone appearance on the artificial marble.

Therefore, in order to solve such a problem, a method of using natural ore as particles can be considered. In this case, although the appearance close to that of natural stone is obtained, natural ore is generally hard. Therefore, there is a problem that it is inferior in post-processability and lacks in stability of color tone and pattern due to being a natural product.

Further, as a method for producing a resin molded product having a pattern in which irregularly-shaped small pieces are scattered, a method of molding by mixing a resin molding material and colored film-like small pieces (Japanese Patent Laid-Open No. Hei 10-1999) No. 7-256766) is also known, but in this manufacturing method, since a film-shaped piece simply colored in a predetermined color is used, an artificial marble having a natural stone appearance can be obtained. Have difficulty. That is, it is difficult to easily manufacture the artificial marble that can satisfy the reduction of the manufacturing cost and the stable appearance of the natural stone at the same time by any of the above methods.

The present invention has been made in view of the above circumstances, and an object of the present invention is to provide a natural stone-tone decorative molded product which is inexpensive and which can obtain a stable natural stone-tone appearance. It is in. In addition to the object of the invention of claim 1, the object of the invention of claim 2 is to provide a natural stone-like decorative molded product that can print a predetermined pattern well and obtain a more stable natural stone-like appearance. The object of the invention according to claim 3 is, in addition to the object of the invention according to claim 1 or 2, that the outline of the particles for decoration is blurred and the pattern is clearly visible to give a natural stone appearance closer to that of natural stone. It is to provide a decorative molded article. The object of the invention of claim 4 is
It is an object of the present invention to provide a method for producing a natural stone tone decorative molded product that can be produced at low cost and that can easily form an artificial marble having a stable natural stone tone appearance.

[0008]

In order to achieve such an object, the invention according to claim 1 of the present invention is to cure and mold a compound for a decorative molded article, wherein a curable resin liquid is mixed with decorative particles. In the natural stone tone decorative molded product formed by
The decorative particles are characterized by being formed into a flat particle shape by cutting a fiber sheet on which a natural stone pattern is printed in advance.

With such a constitution, the decorating particles to be mixed with the curable resin liquid are formed into flat particles by cutting the fiber sheet on which the natural stone pattern is printed in advance. , It is possible to prevent the pattern (pattern) of the individual particles for decoration from becoming monotonous, and it is possible to easily obtain a decorative molded article having an appearance close to that of natural stone, and to print a predetermined pattern on the fiber sheet in advance. Since it can be dealt with by itself, an inexpensive decorated molded product can be obtained.

The invention according to claim 2 is characterized in that the fibrous sheet is made of non-woven fabric, paper, mat or cloth. By configuring in this way,
Since a non-woven fabric, paper, or the like that is easy to print is used as the fiber sheet, the fiber sheet itself can be printed with a good pattern, and the artificial marble provides a stable natural stone-like appearance.

Further, the invention according to claim 3 is characterized in that the color tone of the printed fiber sheet is set to be similar to the color tone of the compound for decorative molding. By configuring in this way, it is possible to blur the outline of the particles for decoration to be blended in the compound for decorative molding with a color tone similar to each other, and only the pattern printed on the particles for decoration is visible. As a result, it is possible to easily obtain a natural color decorative molded product having an appearance closer to that of natural stone.

Further, according to the invention of claim 4, after the fiber sheet on which a natural stone pattern is printed in advance is cut to produce flat particle-shaped decorating particles, the decorating particles are hardened with a curable resin. It is characterized in that a compound for a decorative molded product is prepared by mixing it with a liquid, and the compound for a decorative molded product is cured and molded.

With such a constitution, a predetermined pattern is printed in advance on the fiber sheet, and the printed fiber sheet is cut to produce small flat particles for decoration, and this decoration particle is used. By mixing the particles in a curable resin liquid and curing and molding the liquid, a natural stone-tone decorated molded product is manufactured. Since the particles for decoration are produced by cutting the printed fiber sheet, the manufacturing cost of the particles for decoration itself becomes low, and by setting the print pattern on the fiber sheet to a predetermined value, It is possible to prevent the color tone of the individual particles for decoration from becoming monotonous, and it is possible to easily obtain a decorated molded product having a natural stone tone appearance.

[0014]

BEST MODE FOR CARRYING OUT THE INVENTION Embodiments of the present invention will be described in detail below with reference to the drawings. 1 to 4 show an embodiment of a method for producing a natural stone tone decorative molded product according to the present invention,
1 is a perspective view schematically showing an artificial marble manufactured by the manufacturing method, and FIG. 2 is a process diagram showing an example of the manufacturing method.
FIG. 3 is an explanatory view of the main part, and FIG. 4 is a perspective view of the decorative particles in a cut state.

In FIG. 1, the artificial marble 1 has a natural stone-like pattern on its surface 1a by mixing a large number of decorative particles 3 in a resin molding material 2 (curable resin liquid) in an irregular state. Is formed. In addition, although the figure shows the case where the outline of the decorating particles 3 can be visually recognized, for example, the color tone of the resin molding material 2 and the color tone of the fiber sheet 4 forming the decorating particles 3 described later. By making them substantially similar to each other, it is possible to set the outline of the decorating particles 3 to be blurred so that they are hardly visible.

Then, as shown in FIG. 2, the artificial marble 1 is manufactured through three steps of a particle producing step K1, a molding step K2 and a finishing step K3. That is, first, in the particle production step K1, as shown in FIG. 3 (a), at least one surface 4a of the front and back surfaces of the prepared fiber sheet 4 has a natural stone pattern as shown in FIG. 3 (b). 5 is gravure printed (K11). As the fiber sheet 4, a non-woven fabric having an appropriate length, width and thickness,
Paper, mat, cloth or the like is used, and the front and back surfaces thereof are subjected to an antistatic treatment, if necessary.

After the pattern 5 is printed on the fiber sheet 4 in the printing step K11, the fiber sheet 4 is cut and crushed (K12) by, for example, a cutting mill as shown in FIG. 3C. As a result of this cutting, as shown in FIG. 4, a flat-shaped particle material 3a having a square small particle with a side dimension of, for example, about 1 mm to 20 mm and having a pattern on its surface
By pulverizing each of the particle materials 3a, as shown in FIG. 3 (d), decorative particles 3 whose outer shape is random (irregular) are produced.

The decorative particles 3 are not limited to the use after cutting and crushing shown in FIG. 3 (c), but may be in the cut state (state of the particle material 3a) shown in FIG. 3 (c), for example. It can be used, or as shown in FIGS. 5 (a) to 5 (c), its outer shape is cut into a rhombus, a circle including an ellipse, or a polygonal shape and used as it is or after crushing it. In other words, the decoration particles 3 (or the particle material 3a) having various small and flat shapes can be used.

After the decorating particles 3 are produced in this way, the step moves to a molding step K2 shown in FIG. In the molding step K2, first, the decorating particles 3 are added / mixed to a compound in which a transparent curable resin liquid as a curable resin liquid, a filler, a coloring agent, a curing agent and the like are blended in predetermined parts by weight (K21). Then, a compound for artificial marble is produced. As the transparent curable resin liquid used at this time, for example, unsaturated polyester resin, acrylic syrup, etc. are used, and the blending amount of the decorating particles 3 to the transparent curable resin liquid is 100% by weight of the transparent curable resin liquid. It is set to about 1 to 100 parts by weight with respect to parts.

As the filler, for example, aluminum hydroxide, magnesium hydroxide, calcium carbonate, glass filler or the like having an average particle size of about 5 μm to several tens of μm is used, and the amount thereof is a transparent curable resin. It is set within a range that does not impair the transparency of the liquid. Further, as the colorant, TiO ₂ , Fe ₂ O ₃ , yellow toner, brown toner, blue toner, green toner or the like is used, and the blending amount of this colorant also impairs the transparency of the transparent curable resin liquid. It is set to a range that does not exist. Furthermore, as the curing agent, a curing accelerator such as cobalt naphthenate, a radical curing agent, or the like is used.
About 0 to 1 part by weight and 0.5 to 2 parts by weight are added to 00 parts by weight.

When the artificial marble compound produced with such a composition is agitated by an agitator, the directions of the mixed flat particles 3 for decoration are random. This compound for artificial marble is poured into a mold of a predetermined shape and cured / molded (K2
By 1), a cured product (matrix) is obtained. This completes the molding process, takes out the cured product obtained in this molding process from the mold, and carries out a finishing process K3 in which the surface of the cured product is polished by sanding or the like to produce an artificial marble 1 such as so-called marborone. To be done.

Further, the compound for artificial marble is applied to the inner wall of a mold, and after gelling, a fiber reinforced resin molded article is formed by a usual hand lay-up method or a spray-up method, and the gel coat layer is an artificial marble. It is possible to obtain a fiber-reinforced resin type decorative molded product having the above layer. Furthermore, the compound for artificial marble is applied to the surface of the desired object and cured to form a decorative molded product having a layer of artificial marble, or it is poured into a mold and cured and molded to give an artificial marble-like decorative molding. The decorative molded article is useful as a kitchen cowter, bathtub or the like.

As described above, in the artificial marble 1 of the above-mentioned embodiment, the decorative particles 3 blended in the transparent curable resin liquid.
Is produced by cutting and crushing the fiber sheet 4 on which the predetermined pattern 5 is printed. Therefore, when the fiber sheet 4 is printed and cut, the conventional resin cured product is crushed, classified and bonded. Compared to, it becomes easier and the particles for decoration 3
The manufacturing cost of itself can be reduced, and the inexpensive artificial marble 1 can be easily obtained.

In particular, since a relatively easy-to-print material such as non-woven fabric or paper is used as the fibrous sheet 4 for forming the decorating particles 3, a natural stone tone pattern is better than, for example, a resin film. Since it is possible to print and stabilize the pattern of each decorating particle 3 itself, and the fiber sheet 4 itself has a predetermined flexibility (flexibility), the decorating particle 3 is made of artificial marble. When added / mixed to the compound for
The artificial marble 1 makes it possible to more easily obtain a stable natural stone-like appearance, such as a good random state being obtained in the compound.

On the surface of a relatively large fiber sheet 4, a pattern 5 for obtaining a natural stone tone pattern is printed in advance, and the pattern 5 is cut and crushed to have a predetermined size of an outer shape 3 for decoration. It is possible to easily make the patterns of the individual decorative particles 3 different by setting the pattern 5, and it is possible to prevent the color tone of the decorative particles 3 from becoming monotonous. It is possible to obtain a natural stone pattern with excellent texture.

Furthermore, since it is possible to easily set the pattern of each of the particles 3 for decoration, it is possible to obtain a stable natural stone tone pattern, and for example, the fiber sheet 4 (or the pattern to be printed). ) And the color tone of the compound for artificial marble are set to be substantially the same, it is possible to visually recognize only the pattern by blurring the outline of each of the particles 3 for decoration, and from these facts, the artificial stone of a predetermined natural stone tone is obtained. Marble 1 can be stably produced.

When the fiber sheet 4 is subjected to antistatic treatment, the fiber sheet 4 on which the pattern 5 is printed is cut to produce the decorating particles 3, or after the fabrication.
Surely prevent dust and the like from adhering to the front surface (including the back surface) of the fiber sheet 4 and the decorative particles 3 during the process of storing and storing the mixture in a transparent curable resin liquid and curing and molding. The printed pattern 5 itself can be stabilized, and the desired natural stone-like artificial marble 1 based on the preset pattern 5 can be manufactured more easily.

In the above examples, the case where the shape of the decorative particles 3 mixed in the curable resin liquid is one kind has been described. For example, a plurality of kinds of decorative particles 3 having different shapes are simultaneously used. It is also possible to mix them to prepare a compound for a decorative molded product. Further, in the above examples, the manufacturing process, the material and transparency of the fiber sheet, the compounding examples of the compound for decorative molded articles and the transparency thereof are examples, and for example, a translucent curable resin liquid is used. Various modifications can be made without departing from the gist of each invention related to the present invention.

[0029]

As described in detail above, according to the first aspect of the present invention, the particles for decoration mixed in the curable resin liquid are
Since it is formed into a flat particle shape by cutting a fiber sheet on which a natural stone tone pattern is printed in advance, it is possible to prevent the pattern (pattern) of individual decorating particles from becoming monotonous.
It is possible to easily obtain a decorative molded product having an appearance close to that of natural stone, and it is possible to obtain an inexpensive decorative molded product because it can be dealt with only by printing a predetermined pattern on the fiber sheet in advance.

According to the invention described in claim 2, in addition to the effect of the invention described in claim 1, since the fiber sheet is made of a non-woven fabric, paper, mat or cloth which is easy to print, the fiber is used. It is possible to satisfactorily print a predetermined pattern on the sheet itself, and to obtain a stable natural stone-like appearance by the decorative molded product.

According to the invention described in claim 3, in addition to the effect of the invention described in claim 1 or 2, a color tone in which the outlines of the particles for decoration mixed in the compound for decorative molded articles are similar to each other Since it can be blurred, only the pattern printed on the particles for decoration can be visually recognized, and a natural color decorative molded product having an appearance closer to that of natural stone can be easily obtained.

According to the invention described in claim 4, the fiber sheet on which a predetermined pattern is printed in advance is cut to produce small flat particles for decorating, and the particles are used in a curable resin liquid. Since a natural stone-like decorative molded product is produced by blending with and being hardened, it is possible to manufacture the decorative particles themselves at low cost, and to set the print pattern on the fiber sheet to a predetermined value. With this, it is possible to prevent the color tone of each of the particles for decoration from becoming monotonous, and it is possible to easily obtain a decorated molded product having a natural stone appearance.

[Brief description of drawings]

FIG. 1 is a perspective view showing an embodiment in which a natural stone-like decorative molded product according to the present invention is applied to artificial marble.

FIG. 2 is a process drawing showing an example of the manufacturing method thereof.

FIG. 3 is an explanatory diagram of its main part.

FIG. 4 is a perspective view of the decorative particles in the cut state.

FIG. 5 is a plan view showing a modified example of the same decorative particle.

[Explanation of symbols]

1 ... Fiber sheet 2 Curable liquid resin 3 ... Decorative particles 4 ... Fiber sheet 5 ... pattern

Claims (4)

(57) [Claims] 1. A natural stone tone decorative molded article formed by curing and molding a compound for decorative molded article, wherein a decorative particle is mixed with a curable resin liquid, wherein the decorating particle has a natural stone tone in advance. A natural stone tone decorative molded product, characterized by being formed into flat particles by cutting a fiber sheet on which the pattern of (1) is printed. 2. The fiber sheet is a non-woven fabric, paper, mat,
The natural stone decorative molded article according to claim 1, wherein any one of the cloths is used. 3. The natural stone tone decorative molded article according to claim 1, wherein the color tone of the printed fiber sheet is set to be similar to the color tone of the decorative molded article compound. 4. A fibrous sheet on which a natural stone pattern is printed in advance is cut to prepare flat particles for decoration,
Manufacture of a natural stone tone decorative molded product, characterized in that the decorative particles are blended with a curable resin liquid to prepare a compound for decorative molded product, and the compound for decorative molded product is cured and molded. Method.