JP3683503B2

JP3683503B2 - Artificial stone manufacturing method and joining method

Info

Publication number: JP3683503B2
Application number: JP2001031337A
Authority: JP
Inventors: 嘉行和田
Original assignee: 和田商事株式会社
Priority date: 2001-02-07
Filing date: 2001-02-07
Publication date: 2005-08-17
Anticipated expiration: 2021-02-07
Also published as: JP2002234037A

Description

【０００１】
【発明の属する技術分野】
本発明は、不飽和ポリエステル樹脂を使用した人工石材の製造方法、及び人工石材の接合方法に関する。
【０００２】
【従来の技術】
従来、不飽和ポリエステル樹脂を結合材に使用した人工石材の注型製造では、主に下記に示す製造方法が使用されていた。これらの方法は、いずれも製造後の外観がきれいであり、しかも簡易な設備で効率よく生産できるという利点を有している。
（１）天然石の砕石を主原料とし、不飽和ポリエステル樹脂を結合材に使用して天然御影石風に成形する方法。
（２）不飽和ポリエステル樹脂と無機充填材を有するコンパウンドに顔料等で着色し、単色あるいは様々な模様を表出する方法。
（３）天然大理石柄やオニックス柄を複写した特殊なシートをバックアップ材の表面に不飽和ポリエステル樹脂で封止してその絵柄を透かせて表示する方法。
【０００３】
【発明が解決しようとする課題】
しかしながら、これらの注型方法では、人工石材の表面に保護膜を形成し表面強度を向上させるため、ポリエステル樹脂等の透明樹脂膜を生成するゲルコートを型枠の内表面に施すことが共通に行なわれている。しかし、人工石材の表面に保護膜を形成することは、成形後の成品を加工する際に種々の問題が発生する要因となっていた。例えば、切断等の平面加工は容易に行なえるが、切断後の切断面の磨き加工や、面取り等の加工に多大な時間を要していた。また、切断面の研磨を行なう際は、先ず発生したピンホールを埋めつぶし、次にゲルコートを再被覆しなければならず、この作業は人手のかかる熟練を要する作業であるため、コスト高の主要因となっていた。更に、ゲルコートの再被覆が微妙に変化すると表面の美観を損なうという問題も発生した。そこで、注型法では型枠の表面にゲルコートを施さないノンゲルコート工法も実用化されている。
【０００４】
しかし、注型方法では必然的にＦＲＰ、金属、ガラス等の材料を用いて成形用の型枠を作成しなければならず、規格商品のように形状が標準化された型枠で製造する場合は原価構成中に占める型枠費の割合は小さくコスト的に十分対応できるが、形状が特殊となると専用の型枠をその都度製作する必要が生じ、型枠に多大なコストを要して製造コストが高騰しコスト的に採算が合わなくなる。また、人工石材と人工石材の接合部分の処理には、シリコーン樹脂のコーキング、あるいは人工石材の原料を継ぎ目に流し込み硬化後研磨する方法等があるが、いずれも接合部分の境界ラインは目視で確認できるものであり、人工石材を用いて構成された構造物の美観を損ねていた。
本発明はかかる事情に鑑みてなされたもので、注型法のノンゲルコート工法で表面美観に優れ成形後の加工が容易な高強度の人工石材の製造方法、及び得られた人工石材間の接合境界が目立たない接合方法を提供することを目的とする。
【０００５】
【課題を解決するための手段】
前記目的に沿う第１の発明に係る人工石材の製造方法は、不飽和ポリエステル樹脂１００重量部に対して、微粉の無機質充填材１５０〜３００重量部、硬化剤０．４〜３．８重量部、硬化促進剤０．４〜１．３重量部、及び少量の着色顔料を含む母材に、石目調模様を形成する所定量の粒状の模様表出材を加え、混合機で撹拌混合しながら脱泡を行なって適度の流動性を有するベースコンパウンドを作る第１工程と、前記ベースコンパウンドを型枠内に注入し常温硬化させて１次硬化体を形成する第２工程と、前記１次硬化体を前記型枠より脱型し熱処理装置に装入して加熱硬化させ人工石材とする第３工程とを有する。
【０００６】
不飽和ポリエステル樹脂に硬化剤、及び硬化促進剤を加えて十分に混合すると、不飽和ポリエステル樹脂に重合反応が生じ徐々に硬化して硬質状態となる。このため、種々の石材の色合いや質感を人工的に調整するための微粉の無機質充填材、着色顔料、及び石目調模様を形成する粒状の模様表出材を、不飽和ポリエステル樹脂、硬化剤、硬化促進剤と共に混合してベースコンパウンドを作製し、型枠に流し込んで硬化させることにより任意の形状、寸法の人工石材を製造することができる。更に、ポリエステル樹脂は透光性であるため、内部の構造を透かして見ることができ、奥行感のある人工石材を得ることができる。
硬化剤としては有機過酸化物系の硬化剤、例えば５５％濃度の過酸化メチルエチルケトンを使用することができる。また硬化を促進する硬化促進剤としては、例えば１％濃度のナフテン酸コバルトを使用することができる。加える硬化剤と硬化促進剤の量は、硬化剤と硬化促進剤の種類により変化するが、不飽和ポリエステル１００重量部に対して、硬化剤を０．４〜３．８重量部、好ましくは０．４〜３．０重量部の範囲とし、硬化促進剤を０．４〜１．３重量部、好ましくは０．４〜１．０重量部の範囲とすれば、夏場、冬場を通じて十分な可使時間を確保して不飽和ポリエステル樹脂を硬化させることができる。
【０００７】
微粉の無機質充填材は、不飽和ポリエステル樹脂の硬化時の収縮の緩和と、人工石材に質感を具備させるために使用するもので、不飽和ポリエステル樹脂１００重量部に対して１５０〜３００重量部の範囲で加えるのがよい。無機質充填材の量が１５０重量部未満では不飽和ポリエステル樹脂の硬化時の収縮緩和の効果が不十分で、３００重量部を超えて加えると人工石材の強度が低下してしまう。無機質充填材としては、水酸化アルミニウム、炭酸カルシウム、タルク、寒水石等が使用できる。着色顔料は、人工石材の母材部分に種々の色を付与するために使用するもので、市販のポリエステル用着色顔料を使用することができる。使用量は少量で不飽和ポリエステル樹脂１００重量部に対して着色顔料は０．０４〜１．３重量部の範囲で十分である。加える量が０．０４重量部未満では母材を着色する効果が少なく、１．３重量部を超えて加えると、母材の着色が過度となり得られる人工石材の美観、質感が低下する。母材に対して加える粒状の模様表出材は、石材としての模様を表面に表出させるもので、使用する模様表出材の種類、形状、色、使用料等を変化することで人工石材に天然の石材と同様の色合い、質感を付与することができる。
【０００８】
第１工程では、飽和ポリエステル樹脂、微粉の無機質充填材、着色顔料、硬化剤、及び硬化促進剤を混合機で撹拌混合しながら脱泡を行なって母材を作り、母材に対して所定量の模様表出材を加え混合してベースコンパウンドを作製する。脱泡を行なうことで、模様表出材の周囲を充填している母材部分にピンホール状の穴が形成されるのを防止できる。第２工程では、型枠に注入したベースコンパウンドを、常温（例えば、１５〜３０℃）で、４〜１５時間放置して不飽和ポリエステルを重合させることにより１次硬化体を形成する。第３工程では、１次硬化体を、例えば温度８０〜８５℃の雰囲気中で、３〜４時間の加熱処理して１次硬化体の硬度を上昇させて最終硬化体とする。なお、加熱硬化することにより、深みのある色合いが出現し、石目調、マーブル調としての風格が備わる。加熱硬化する温度が８０℃未満であると表面硬度の上昇が低く、人工石材の表面に疵が付き易く好ましくない。また、８５℃を超えた温度で加熱硬化すると、１次硬化体に変形が生じてしまうので好ましくない。加熱硬化処理の温度を８０〜８５℃の範囲に設定すると、３〜４時間の処理で十分な硬度上昇を起こさせることができる。処理時間が３時間未満であると、十分な硬度上昇が得られず、４時間を超えて処理しても更なる硬度の上昇は起こらず生産性が低下する。このため、加熱硬化の条件を、８０〜８５℃の温度範囲で３〜４時間処理とするのがよい。
【０００９】
第１の発明に係る人工石材の製造方法において、前記模様表出材として、着色した鱗片状酸化アルミナ系模様表出材を使用する。
鱗片状酸化アルミナ系模様表出材の寸法は、例えば厚さが０．１〜０．５ｍｍ、鱗片の寸法が０．５〜３ｍｍのものが使用できる。着色した鱗片状酸化アルミナ系模様表出材を母材中に分散することで、石目調を有する人工石材を調整することができる。使用する鱗片状酸化アルミナ系模様表出材の色と、加える量は製造する石材の要求に応じてその都度調整する。
【００１０】
第１の発明に係る人工石材の製造方法において、前記模様表出材として、水酸化アルミニウム１００重量部に対して不飽和ポリエステル樹脂２４〜２６重量部、硬化剤０．１〜１重量部、硬化促進剤０．１〜０．４重量部、及び少量のポリエステル用着色顔料を加えた混合物を硬化させ破砕して形成した合成粒を使用することが好ましい。
合成粒としては、０．５〜３ｍｍの寸法のものが使用できる。合成粒を使用することにより、石目調を有する人工石材を調整することができる。ここで、不飽和ポリエステル樹脂を２６重量部を超えて加えると、合成粒の比重が小さくなり、型枠内に注入されたベースコンパウンド中で合成粒が上表面に浮き上がってくる。また、不飽和ポリエステル樹脂を２４重量部未満となるように加えると、合成粒の比重が大きくなり、型枠内で合成粒が底に沈む。従って、水酸化アルミニウム１００重量部に対して不飽和ポリエステル樹脂を２４〜２６重量部と規定し、合成粒の比重を調整し、合成粒が母材中で偏って存在しないようにしている。
また、着色顔料の量は不飽和ポリエステル樹脂１００重量部に対して０．０１〜０．４重量部加えるのがよい。合成粒に最適な色を付けるには、０．０１重量部未満の使用料では母材とのコントラストが付きにくく、０．４重量部を超えて加えると母材とのコントラストが過度となって好ましくない。
硬化剤としては有機過酸化物系の硬化剤、例えば５５％濃度の過酸化メチルエチルケトンを使用することができる。また硬化を促進する硬化促進剤としては、例えば１％濃度のナフテン酸コバルトを使用することができる。硬化剤と硬化促進剤の種類により加える硬化剤と硬化促進剤の量は変化するが、不飽和ポリエステル２４〜２６重量部に対して、硬化剤０．１〜１重量部、硬化促進剤０．１〜０．４重量部の範囲であれば、夏場、冬場を通じて十分な可使時間を確保して不飽和ポリエステル樹脂を硬化させることができる。
母材に加える合成粒の量は製造する石材の要求に応じてその都度調整する。水酸化アルミニウム、不飽和ポリエステル樹脂、及び着色顔料の混合物の硬化は、常温硬化（例えば、１５〜３０℃で、４〜１５時間）、加熱硬化（例えば、８０〜８５℃の雰囲気中で、３〜４時間）いずれの方法で行なってもよい。
【００１１】
前記目的に沿う第２の発明に係る人工石材の製造方法は、不飽和ポリエステル樹脂１００重量部に対して、微粉の無機質充填材１５０〜３００重量部、硬化剤０．４〜３．８重量部、硬化促進剤０．４〜１．３重量部、及び少量の着色顔料を混合機で撹拌混合しながら脱泡を行なって適度の流動性を有する母材を作る第１工程と、高粘性の不飽和ポリエステル樹脂１００重量部に対して硬化剤０．４〜３．８重量部、硬化促進剤０．４〜１．３重量部、及び所定量の着色顔料を加えて均一に撹拌混合しながら脱泡して、オニックス調模様を形成する流動性絵柄材を調整する第２工程と、前記母材１００重量部に対して前記流動性絵柄材を０．０２〜１重量部の割合で加えて該流動性絵柄材を前記母材中に縞模様状に分散させたベースコンパウンドを作る第３工程と、前記ベースコンパウンドを型枠内に注入し常温硬化させて１次硬化体を形成する第４工程と、前記１次硬化体を前記型枠より脱型し熱処理装置に装入して加熱硬化させ人工石材とする第５工程とを有する。
【００１２】
流動性絵柄材に使用する高粘性の不飽和ポリエステル樹脂は、例えば粘性が１５００〜２０００ミリパスカル秒のものを使用することができる。また、着色顔料の色と使用量は、製造する石材の要求に応じてその都度調整する。事前に調整した母材１００重量部に対して、流動性絵柄材を０．０２〜１重量部加えて、例えば手動撹拌機で容器内の任意の数カ所をそれぞれ数秒間ずつ撹拌する。母材の粘性に比較して流動性絵柄材の粘性は、例えば３〜４倍大きいので、手動撹拌機で任意の数カ所をそれぞれ数秒間程度撹拌しただけでは、ベースコンパウンドは不均質な混合状態にしかならず、母材中に加えた流動性絵柄材が縞状に混じり合った状態になる。そのため、型枠にベースコンパウンドを注入する際の注ぎ口の寸法、注入速度を変えることにより、型枠内での流動性絵柄材の分散形態を制御することができる。例えば、注入速度が遅いと縞模様の間隔が広く、注入速度が速いと縞模様の間隔が狭くなる。型枠内で縞模様状に存在している流動性絵柄材は、ベースコンパウンドに比較して粘性が高いので、相互に混じり合うことはない。この状態で硬化処理を行なうことで、ベースコンパウンド中に縞模様の流動性絵柄材を硬化させ固定することができる。
【００１３】
第１、及び第２の発明に係る人工石材の製造方法において、前記第１工程で前記母材を作る際に、該母材１００重量部に対して消泡剤を０．５〜２重量部加えることが好ましい。
消泡剤を０．５〜２重量部加えることにより、不飽和ポリエステル樹脂、微粉の無機質充填材、着色顔料、硬化剤、硬化促進剤、及び模様表出材（又は流動性絵柄材）を加えて混合する際に巻き込まれる空気を短時間に効率的に除去することができる。ここで、消泡剤としては、市販のポリエステル用消泡剤が使用できる。
【００１４】
前記目的に沿う本発明の一実施の形態に係る人工石材の接合方法は、不飽和ポリエステル樹脂、微粉の無機質充填材、硬化剤、硬化促進剤、及び少量の着色顔料を撹拌混合しながら脱泡を行なって作製した母材に、石目調模様を形成する所定量の粒状の模様表出材、又はオニックス調模様を形成する所定量の流動性絵柄材を混合して作製したベースコンパウンドを、型枠内に注入し常温硬化した後に該型枠より脱型し加熱硬化することにより得られる人工石材の接合方法であって、高粘性で揺変性を有する不飽和ポリエステル樹脂１００重量部に対して、前記人工石材に使用した微粉の無機質充填材と同一の無機質充填材１２０〜１５０重量部、硬化剤０．４〜３．８重量部、硬化促進剤０．４〜１．３重量部、及び前記人工石材に使用した着色顔料と同一の着色顔料を少量加えて混合機で撹拌混合しながら脱泡を行なって接着剤を製造する第１工程と、相互に接合する前記人工石材の間に設けられた隙間に前記接着剤を充填し、該隙間を所定間隔に保持して充填した前記接着剤を硬化させる第２工程と、前記人工石材の表面に付着し硬化した前記接着剤を研磨除去する第３工程とを有する。
【００１５】
接着剤に高粘性で揺変性を有する不飽和ポリエステル樹脂を使用するので、絞り出し器等の接着剤の供給器具に充填して押し出すことにより、人工石材の間の隙間に必要な量の接着剤を充填することができる。また、揺変性を有するため押し出された接着剤は外力が加わらない限り流動しないので、接着剤が充填された隙間を所定間隔に保持して接着剤の硬化が開始するまでの期間、隙間部分に接着剤を確実に固定しておくことができる。なお、接着剤の組成を接合する人工石材の組成に近づけることにより、硬化した接合層は人工石材の母材に近い組織となり、接合境界が目立たなくなる。このため、接着剤を、高粘性で揺変性を有する不飽和ポリエステル樹脂１００重量部に対して、人工石材に使用した微粉の無機質充填材と同一の無機質充填材１２０〜１５０重量部、硬化剤０．４〜３．８重量部、硬化促進剤０．４〜１．３重量部、及び人工石材に使用した着色顔料と同一の着色顔料を少量加える構成とした。なお、無機質充填材を１２０重量部未満とすると人工石材の母材に近い組織が得られず、１５０重量部を超えて無機質充填材を使用すると人工石材との接着性が低下する。そのため、無機質充填材の使用料を１２０〜１５０重量部と規定した。
【００１６】
【発明の実施の形態】
続いて、添付した図面を参照しつつ、本発明を具体化した実施の形態につき説明し、本発明の理解に供する。
ここに、図１は本発明の第１の実施の形態に係る人工石材の製造方法でベースコンパウンドを型枠に注入した状態を示す断面図、図２は本発明の第２の実施の形態に係る人工石材の製造方法でベースコンパウンドを型枠に注入した状態を示す断面図、図３は本発明の第３の実施の形態に係る人工石材の製造方法でベースコンパウンドを型枠に注入した状態を示す斜視断面図、図４（ａ）、（ｂ）、（ｃ）はそれぞれ本発明の第１〜第３の実施の形態に係る人工石材の製造方法を適用して製造した人工石材の断面図、図５は本発明の一実施の形態に係る人工石材の接合方法を適用した人工石材の接合前の配置を示す断面図、図６は同人工石材の接合方法を適用した人工石材の接合時の状態を説明する断面図である。
【００１７】
本発明の第１の実施の形態に係る人工石材の製造方法について詳細に説明する。粘性が５００ミリパスカル秒程度の不飽和ポリエステル樹脂１００重量部、無機質充填材の一例である粒径が１００μｍ以下で白色度９６以上の水酸化アルミニウム１５０〜３００重量部、表現したい色合いを調整するための着色顔料０．０４〜１．３重量部、硬化剤の一例である５５％濃度の過酸化メチルエチルケトン０．４〜３．８重量部（好ましくは０．４〜３．０重量部）、硬化促進剤の一例である１％濃度のナフテン酸コバルト０．４〜１．３重量部（好ましくは０．４〜１．０重量部）を含む母材１１に、消泡剤の一例である市販のポリエステル用消泡剤を１００重量部の母材１１に対して０．５〜２重量部の割合で添加し、模様表出材として鱗片寸法が０．５〜３ｍｍの着色した鱗片状酸化アルミナ系模様表出材１２を目的とする石目調が表現できる分量加えて、混合機の一例である回転型ミキサーで、例えば１０分間撹拌混合しながら脱泡を行って、ベースコンパウンドを調整する（以上、第１工程）。
【００１８】
図１に示すように、調整して、適度の流動性を有するベースコンパウンドを、市販のワックス系離型剤を塗布した型枠２１内に流し込み、常温で４〜１５時間放置して硬化させ脱型して１次硬化体２２を得る（以上、第２工程）。ここで、型枠２１としては、例えば、底部が平面上の花崗岩、強化ガラス、ステンレス鋼板のいずれか１種からなる底板部２３と、側部がステンレス角鋼管２４で型組され分解可能なものを使用することができる。１次硬化体２２を型枠２１より脱型し熱処理装置の一例であるエアバスに装入して温度８０〜８５℃で３〜４時間保持して加熱硬化させて（第３工程）人工石材１０を製造する。
【００１９】
図４（ａ）に示すように、本発明の第１の実施の形態に係る人工石材の製造方法を適用した人工石材１０は、人工石材１０のマトリックスを形成する母材１１と、母材１１中に分散している着色した鱗片状酸化アルミナ系模様表出材１２とを有している。鱗片状酸化アルミナ系模様表出材１２であるため、型枠２１に流し込まれた際の状況により、人工石材１０の表面１３に対して鱗片状酸化アルミナ系模様表出材１２は種々の方向を向く。例えば、鱗片状酸化アルミナ系模様表出材１２の底面が人工石材１０の表面１３に沿うように配置すると鱗片状酸化アルミナ系模様表出材１２の鱗片部分が表出し、鱗片状酸化アルミナ系模様表出材１２の厚さ部分が人工石材１０の表面１３に沿うように配置すると鱗片状酸化アルミナ系模様表出材１２の厚さ部分が表出する。このため、さまざまな石目調の組織を形成することができる。なお、母材１１は透光性を有しているので、内部に分散している鱗片状酸化アルミナ系模様表出材１２も表面１３から透かして見え、奥行感、重質感を表現することができる。
【００２０】
次に、本発明の第２の実施の形態に係る人工石材の製造方法について詳細に説明する。
先ず、模様表出材として合成粒１６の調整方法について説明する。水酸化アルミニウム１００重量部に対して、粘性が５００ミリパスカル秒程度の不飽和ポリエステル樹脂２４〜２６重量部、硬化剤の一例である５５％濃度の過酸化メチルアチルケトン０．１〜１重量部、硬化促進剤の一例である１％濃度のナフテン酸コバルト０．１〜０．４重量部、及び表現したい色合いを調整するための着色顔料０．０１〜０．４重量部を加えて回転型ミキサーで、例えば１０分間混合して混合物を調整し、例えば厚さ５〜１０ｍｍの箔状に成形したものを常温で４〜１５時間放置して硬化させる。硬化後の板を破砕機で破砕して０．５〜３ｍｍの粒径にすることにより、合成粒１６を製造する。
【００２１】
粘性が５００ミリパスカル秒程度の不飽和ポリエステル樹脂１００重量部、無機質充填材の一例である粒径が１００μｍ以下で白色度９６以上の水酸化アルミニウム１５０〜３００重量部、表現したい色合いを調整するための着色顔料０．０４〜１．３重量部、硬化剤の一例である５５％濃度の過酸化メチルエチルケトン０．４〜３．８重量部（好ましくは０．４〜３．０重量部）、硬化促進剤の一例である１％濃度のナフテン酸コバルト０．４〜１．３重量部（好ましくは０．４〜１．０重量部）を含む母材１５に、消泡剤の一例である市販のポリエステル用消泡剤を１００重量部の母材１５に対して０．５〜２重量部の割合で添加し、製造した合成粒１６を目的とする石目調が表現できる分量加えて、回転型ミキサーで、例えば１０分間撹拌混合して、ベースコンパウンドを作製する（以上、第１工程）。図２に示すように、作製したベースコンパウンドを、市販のワックス系離型剤を塗布した型枠２１内に流し込み、常温で４〜１５時間放置して硬化させ脱型して１次硬化体２５を得る（以上、第２工程）。１次硬化体２５を型枠２１より脱型し熱処理装置の一例であるエアバスに装入して温度８０〜８５℃で３〜４時間保持して加熱硬化させて（第３工程）人工石材１４を製造する。
【００２２】
図４（ｂ）に示すように、本発明の第２の実施の形態に係る人工石材の製造方法を適用した人工石材１４は、人工石材１４のマトリックスを形成する母材１５と、母材１５中に分散している合成粒１６とを有している。合成粒１６は破砕形状を有しているので、いずれの合成粒１６も鮮明に人工石材１４の各表面１７に表出させることができる。なお、母材１５は透光性を有しているので、内部に分散している合成粒１６も表面１７から透かして見え、奥行感、重質感を表現することができる。
【００２３】
続いて、本発明の第３の実施の形態に係る人工石材の製造方法について詳細に説明する。
粘性が５００ミリパスカル秒程度の不飽和ポリエステル樹脂１００重量部、無機質充填材の一例である粒径が１００μｍ以下で白色度９６以上の水酸化アルミニウム１５０〜３００重量部、表現したい色合いを調整するための着色顔料０．０４〜１．３重量部、硬化剤の一例である５５％濃度の過酸化メチルエチルケトン０．４〜３．８重量部（好ましくは０．４〜３．０重量部）、硬化促進剤の一例である１％濃度のナフテン酸コバルト０．４〜１．３重量部（好ましくは０．４〜１．０重量部）を含む母材１９に、消泡剤の一例である市販のポリエステル用消泡剤を１００重量部の母材１９に対して０．５〜２重量部の割合で加えて、回転型ミキサーで、例えば１０分間撹拌混合しながら脱泡して、母材１９を作製する（以上、第１工程）。また、粘性が１５００〜２０００ミリパスカル秒程度の高粘性の不飽和ポリエステル樹脂１００重量部に対して硬化剤の一例である５５％濃度の過酸化メチルエチルケトン０．４〜３．８重量部（好ましくは０．４〜３．０重量部）、硬化促進剤の一例である１％濃度のナフテン酸コバルト０．４〜１．３重量部（好ましくは０．４〜１．０重量部）、及び表現したい色合いを調整するためのポリエステル用着色顔料を加えて回転型ミキサーで、例えば２０分間均一に撹拌混合しながら脱泡して流動性絵柄材２６を作製する（以上、第２工程）。
【００２４】
次に、１００重量部の母材１９に対して、作製した、例えば粘性が９０ｇ／ｃｍｓ程度の流動性絵柄材２６を０．０２〜１重量部の割合で加えて、例えば手動撹拌機で容器内の任意の数カ所をそれぞれ数秒間程度撹拌し母材１９中に加えた流動性絵柄材２６が縞状に混じり合った状態のベースコンパウンドを作製する（以上、第３工程）。図３に示すように、得られたベースコンパウンドを型枠２１内に注入する。このとき、型枠２１にベースコンパウンドを注入する際の注ぎ口の口径を任意に調整しながら、更に注入速度も変動させながら注入を行なう。これによって、流動性絵柄材２６により形成する縞模様の間隔や厚さを調整できる。型枠２１内で縞模様状に存在している流動性絵柄材２６は、母材１９に比較して粘性が高いので、相互に混じり合うことはなく、注入された時に形成される縞模様の状態がそのまま維持される。従って、この状態のまま常温で４〜１５時間放置して硬化させ脱型すると、注入したときに形成された縞模様が表出した１次硬化体２７が得られる（以上、第４工程）。１次硬化体２７を型枠２１より脱型し熱処理装置の一例であるエアバスに装入して温度８０〜８５℃で３〜４時間保持して加熱硬化させて（第５工程）人工石材１８を製造する。
【００２５】
図４（ｃ）に示すように、本発明の第３の実施の形態に係る人工石材の製造方法を適用した人工石材１８は、人工石材１８のマトリックスを形成する母材１９と、母材１９中に混合された流動性絵柄材２６が型枠２１に流し込まれた際に形成した縞模様部分が硬化した縞状部２０とを有している。縞状部２０はマトリックス中に複雑に形成されており、しかもマトリックスが透光性を有しているため、非常に深みのある立体的で重質感のあるオニックス調の人工石材１８を製造することができる。
【００２６】
本発明の一実施の形態に係る人工石材の接合方法について詳細に説明する。ここで、本実施の形態に係る人工石材の接合方法は、接合に使用する接着剤３２（図６参照）の調整と、接着剤３２で人工石材１０を接合する接合操作から構成されているので、接着剤３２の調整と、接合操作に分けてそれぞれ詳細に説明する。接着剤３２の調整は、下記のようにして行なった。例えば、粘性が１５００〜２０００センチポイズ程度の高粘性で揺変性を有する不飽和ポリエステル樹脂１００重量部に対して人工石材に使用した微粉の無機質充填材と同一の無機質充填材１２０〜１５０重量部、人工石材に使用した着色顔料と同一の着色顔料０．０４〜１．３重量部、硬化剤の一例である５５％濃度の過酸化メチルエチルケトン０．４〜３．８重量部（好ましくは０．４〜３．０重量部）、及び硬化促進剤の一例である１％濃度のナフテン酸コバルト０．４〜１．３重量部（好ましくは０．４〜１．０重量部）を混合機の一例である回転式ミキサーで、例えば２０分撹拌混合しながら脱泡を行なって作製する（第１工程）。なお、脱泡を完全に行なうには、調整した接着剤を容器に入れて振動台の上に載せて振動をかけて、内部の気泡を表面に浮き上がらせて除去する操作を加えてもよい。
【００２７】
接合操作は下記のようにして行なった。先ず、前記実施の形態に係る人工石材の製造方法を適用して製造した人工石材１０の接合面２８のコーナー部分に、例えば３２０番の紙ヤスリで軽く研削して糸面２９を形成する。次に、ラッカーシンナー等の有機溶剤で接合面２８及び接合面２８近傍の汚れを除去する。更に、人工石材１０の一方の面に例えば鋼片で作製したブロック状のクランプ固定用治具３０を、例えば瞬間接着剤で点付けする。クランプ固定用治具３０が接着された面を上面として人工石材１０を平坦な接合用台３１の上に、人工石材１０の各接合面２８の間隔が、例えば２〜３ｍｍとなるように配置する。
絞り出し器等の供給器具に充填した接着剤３２を、人工石材１０の各接合面２８の間に設けられた隙間に充填する。接着剤３２を充填した後、各クランプ固定用治具３０間にクランプ３３を取付けて、隙間が例えば０．５〜１ｍｍとなるまで締めつける。人工石材１０の接合面２８の間に設けられた隙間の間隔を小さくすることにより、人工石材２８の接合面２８と接着剤３２とのなじみを向上させることができる。隙間を小さくすることにより、余分な接着剤３２は上面側に流出してくる。この状態で、常温で４〜１５時間放置して硬化させる。なお、硬化は４０〜５０℃の加熱した雰囲気中で１〜４時間保持することにより行なうこともできる（第２工程）。硬化完了後、表面に流出して硬化した接着剤３２を研磨除去する（第３工程）。
【００２８】
以上、本発明の実施の形態を説明したが、本発明は、この実施の形態に限定されるものではなく、例えば、微粉の無機質充填材として水酸化アルミニウムを使用したが、炭酸カルシウム、タルク、寒水石を使用することも可能である。消泡剤として、市販のポリエステル用消泡剤を使用したが、市販のシリコーンを含有しない破泡性の界面活性剤を組み合わせて使用することも可能である。また、消泡剤を加えて脱泡する際、減圧下で撹拌混合を行なうと、より効果的に脱泡処理を行なうことができる。
【００２９】
【発明の効果】
請求項１及びこれに従属する請求項３記載の人工石材の製造方法においては、不飽和ポリエステル樹脂、微粉の無機質充填材、硬化剤、硬化促進剤、及び少量の着色顔料を含む母材に、石目調模様を形成する所定量の粒状の模様表出材を加え、混合機で撹拌混合しながら脱泡を行なって適度の流動性を有するベースコンパウンドを作る第１工程と、ベースコンパウンドを型枠内に注入し常温硬化させて１次硬化体を形成する第２工程と、１次硬化体を型枠より脱型し熱処理装置に装入して加熱硬化させ人工石材とする第３工程とを有するので、注型法のノンゲルコート工法により高強度で表面美観に優れ、しかも後加工が容易な人工石材を製造することが可能である。
【００３０】
また、この人工石材の製造方法においては、模様表出材として、着色した鱗片状酸化アルミナ系模様表出材を使用するので、単色、マーブル、石目調等の種々の柄パターン有した人工石材を寸法制約なく製造することができる。
【００３１】
【００３２】
請求項２及びこれに従属する請求項３記載の人工石材の製造方法においては、不飽和ポリエステル樹脂、微粉の無機質充填材、硬化剤、硬化促進剤、及び少量の着色顔料を混合機で撹拌混合しながら脱泡を行なって適度の流動性を有する母材を作る第１工程と、高粘性不飽和ポリエステル樹脂、硬化剤、硬化促進剤、及び所定量の着色顔料を加えて均一に撹拌混合しながら脱泡してオニックス調模様を形成する流動性絵柄材を調整する第２工程と、母材１００重量部に対して流動性絵柄材を０．０２〜１重量部の割合で加えて流動性絵柄材を母材中に縞模様状に分散させたベースコンパウンドを作る第３工程と、ベースコンパウンドを型枠内に注入し常温硬化させて１次硬化体を形成する第４工程と、１次硬化体を型枠より脱型し熱処理装置に装入して加熱硬化させ人工石材とする第５工程とを有するので、非常に深みのある立体的なオニックス調の人工石材を容易に製造することができる。
【００３３】
特に、請求項３記載の人工石材の製造方法においては、第１工程で母材を作る際に、母材１００重量部に対して消泡剤を０．５〜２重量部加えるので、脱泡が十分に行なわれて、内部まで均一な人工石材を製造することが可能となる。このため、切断面に現れるピンホールの埋めつぶし作業がなくなり、加工時間の短縮が可能となって、製造コストの低減が可能となる。
【００３４】
請求項４記載の人工石材の接合方法においては、高粘性で揺変性を有する不飽和ポリエステル樹脂、人工石材に使用した微粉の無機質充填材と同一の無機質充填材、硬化剤、硬化促進剤、及び人工石材に使用した着色顔料と同一の着色顔料を少量加えて混合機で撹拌混合しながら脱泡を行なって接着剤を製造する第１工程と、相互に接合する人工石材の間に設けられた隙間に接着剤を充填し、隙間を所定間隔に保持して充填した接着剤を硬化させる第２工程と、人工石材の表面に付着し硬化した接着剤を研磨除去する第３工程とを有するので、接合箇所が識別しにくい接合を行なうことができ、複雑異形の人工石材を専用の型枠を使用せずに、既存の型枠を用いて製造した人工石材を接合することにより複雑異形の人工石材を容易に、安価で製造することが可能となる。
【図面の簡単な説明】
【図１】本発明の第１の実施の形態に係る人工石材の製造方法でベースコンパウンドを型枠に注入した状態を示す断面図である。
【図２】本発明の第２の実施の形態に係る人工石材の製造方法でベースコンパウンドを型枠に注入した状態を示す断面図である。
【図３】本発明の第３の実施の形態に係る人工石材の製造方法でベースコンパウンドを型枠に注入した状態を示す斜視断面図である。
【図４】（ａ）、（ｂ）、（ｃ）はそれぞれ本発明の第１〜第３の実施の形態に係る人工石材の製造方法を適用して製造した人工石材の断面図である。
【図５】本発明の一実施の形態に係る人工石材の接合方法を適用した人工石材の接合前の配置を示す断面図である。
【図６】同人工石材の接合方法を適用した人工石材の接合時の状態を説明する断面図である。
【符号の説明】
１０：人工石材、１１：母材、１２：鱗片状酸化アルミナ系模様表出材、１３：表面、１４：人工石材、１５：母材、１６：合成粒、１７：表面、１８：人工石材、１９：母材、２０：縞状部、２１：型枠、２２：１次硬化体、２３：底板部、２４：ステンレス角鋼管、２５：１次硬化体、２６：流動性絵柄材、２７：１次硬化体、２８：接合面、２９：糸面、３０：クランプ固定用治具、３１：接合用台、３２：接着剤、３３：クランプ[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a method for producing an artificial stone material using an unsaturated polyester resin, and a method for joining the artificial stone material.
[0002]
[Prior art]
Conventionally, in the cast manufacturing of artificial stone materials using unsaturated polyester resins as binders, the following manufacturing methods have been mainly used. Each of these methods has an advantage that the appearance after production is clean and can be efficiently produced with simple equipment.
(1) A method of forming natural granite-style using crushed natural stone as the main raw material and using unsaturated polyester resin as a binder.
(2) A method of coloring a compound having an unsaturated polyester resin and an inorganic filler with a pigment or the like to display a single color or various patterns.
(3) A method in which a special sheet on which a natural marble pattern or onyx pattern is copied is sealed with an unsaturated polyester resin on the surface of the backup material, and the pattern is displayed through.
[0003]
[Problems to be solved by the invention]
However, in these casting methods, in order to improve the surface strength by forming a protective film on the surface of the artificial stone material, it is commonly performed to apply a gel coat that forms a transparent resin film such as a polyester resin to the inner surface of the mold. It is. However, the formation of a protective film on the surface of the artificial stone material has been a cause of various problems when processing the molded product. For example, planar processing such as cutting can be easily performed, but much time is required for polishing processing of the cut surface after cutting and processing such as chamfering. In addition, when polishing the cut surface, the generated pinhole must be filled first, and then the gel coat must be recoated, and this operation requires labor-intensive skill. It was a cause. In addition, if the re-coating of the gel coat is slightly changed, there is a problem that the aesthetic appearance of the surface is impaired. Therefore, a non-gel coating method in which gel coating is not applied to the surface of the mold has been put into practical use as a casting method.
[0004]
However, the casting method inevitably requires forming molds for molding using materials such as FRP, metal, glass, etc. In case of manufacturing with standardized molds like standard products The ratio of the formwork cost in the cost composition is small and can be handled sufficiently in terms of cost. However, if the shape is special, it will be necessary to produce a dedicated formwork each time, and the formwork will require a great deal of cost and manufacturing costs Soars and becomes unprofitable in terms of cost. In addition, there are methods such as caulking of silicone resin or pouring the raw material of artificial stone into the seam and polishing after curing. It was possible, and it detracted from the aesthetics of structures constructed using artificial stone.
The present invention has been made in view of such circumstances, and a method for producing a high-strength artificial stone material that is excellent in surface aesthetics by a non-gel coating method of a casting method and that can be easily processed after molding, and joining between the obtained artificial stone materials It is an object to provide a joining method in which the boundary is not conspicuous.
[0005]
[Means for Solving the Problems]
The method for producing an artificial stone material according to the first invention in accordance with the above-mentioned object is that, with respect to 100 parts by weight of unsaturated polyester resin, 150 to 300 parts by weight of fine inorganic filler, 0.4 to 3.8 parts by weight of curing agent. In addition, a predetermined amount of a granular pattern display material for forming a stone-like pattern is added to a base material containing 0.4 to 1.3 parts by weight of a curing accelerator and a small amount of a color pigment, and the mixture is stirred and mixed with a mixer. The first step of producing a base compound having moderate fluidity by defoaming, the second step of injecting the base compound into a mold and curing it at room temperature to form a primary cured body, and the primary step And a third step of removing the cured body from the mold, inserting it into a heat treatment apparatus, and heat-curing it to obtain an artificial stone material.
[0006]
When a curing agent and a curing accelerator are added to the unsaturated polyester resin and mixed well, a polymerization reaction occurs in the unsaturated polyester resin and gradually hardens to a hard state. For this reason, finely divided inorganic fillers for artificially adjusting the color and texture of various stone materials, color pigments, and granular pattern display materials that form stone-tone patterns, unsaturated polyester resins, curing agents An artificial stone material having an arbitrary shape and size can be produced by mixing with a curing accelerator to produce a base compound, pouring into a mold and curing. Furthermore, since the polyester resin is translucent, the internal structure can be seen through, and an artificial stone material with a sense of depth can be obtained.
As the curing agent, an organic peroxide-based curing agent such as methyl ethyl ketone peroxide having a concentration of 55% can be used. Moreover, as a hardening accelerator which accelerates | stimulates hardening, 1% concentration cobalt naphthenate can be used, for example. Although the quantity of the hardening | curing agent and hardening accelerator to add changes with kinds of a hardening | curing agent and a hardening accelerator, 0.4-3.8 weight part of hardening | curing agents are preferable with respect to 100 weight part of unsaturated polyester, Preferably it is 0. .4 to 3.0 parts by weight and a curing accelerator in the range of 0.4 to 1.3 parts by weight, preferably in the range of 0.4 to 1.0 parts by weight, is sufficient throughout summer and winter. Unsaturated polyester resin can be cured by securing the working time.
[0007]
The fine inorganic filler is used to relieve the shrinkage of the unsaturated polyester resin upon curing and to give the artificial stone a texture, and is 150 to 300 parts by weight with respect to 100 parts by weight of the unsaturated polyester resin. It is better to add in the range. If the amount of the inorganic filler is less than 150 parts by weight, the shrinkage relaxation effect at the time of curing the unsaturated polyester resin is insufficient, and if it exceeds 300 parts by weight, the strength of the artificial stone material is lowered. As the inorganic filler, aluminum hydroxide, calcium carbonate, talc, cold water stone and the like can be used. The color pigment is used for imparting various colors to the base material portion of the artificial stone material, and a commercially available color pigment for polyester can be used. The amount used is small, and the amount of the color pigment is from 0.04 to 1.3 parts by weight per 100 parts by weight of the unsaturated polyester resin. If the added amount is less than 0.04 parts by weight, the effect of coloring the base material is small, and if added over 1.3 parts by weight, the appearance and texture of the artificial stone material that can be excessively colored the base material is lowered. The granular pattern display material added to the base material is to make the pattern as a stone appear on the surface. By changing the type, shape, color, usage fee, etc. of the pattern display material used, artificial stone material Can be given the same color and texture as natural stone.
[0008]
In the first step, a saturated polyester resin, fine inorganic filler, coloring pigment, curing agent, and curing accelerator are defoamed while mixing with a mixer to make a base material, and a predetermined amount with respect to the base material A base compound is prepared by adding and mixing the pattern display material. By performing defoaming, pinhole-shaped holes can be prevented from being formed in the base material portion filling the periphery of the pattern display material. In the second step, the base compound injected into the mold is left at room temperature (for example, 15 to 30 ° C.) for 4 to 15 hours to polymerize the unsaturated polyester, thereby forming a primary cured body. In the third step, the primary cured body is heated for 3 to 4 hours, for example, in an atmosphere at a temperature of 80 to 85 ° C. to increase the hardness of the primary cured body to obtain a final cured body. In addition, by heat-curing, a deep hue appears, and it has a stone-like tone and marble tone. When the temperature for heat curing is less than 80 ° C., the increase in surface hardness is low, and the surface of the artificial stone is likely to be wrinkled, which is not preferable. Moreover, since it will deform | transform in a primary hardening body when it heat-hardens at the temperature exceeding 85 degreeC, it is unpreferable. When the temperature of the heat curing treatment is set in the range of 80 to 85 ° C., a sufficient increase in hardness can be caused by the treatment for 3 to 4 hours. If the treatment time is less than 3 hours, a sufficient increase in hardness cannot be obtained, and even if the treatment is carried out for more than 4 hours, no further increase in hardness occurs and productivity decreases. For this reason, it is good to set the conditions of heat hardening as a process for 3 to 4 hours in the temperature range of 80-85 degreeC.
[0009]
In the method for producing an artificial stone material according to the first invention, a colored scale-like alumina oxide pattern display material is used as the pattern display material.
For example, the scale-like alumina oxide pattern display material having a thickness of 0.1 to 0.5 mm and a scale of 0.5 to 3 mm can be used. By dispersing the colored scale-like alumina oxide pattern display material in the base material, an artificial stone material having a graininess can be adjusted. The color of the scale-like alumina oxide pattern display material to be used and the amount to be added are adjusted each time according to the requirements of the stone to be produced.
[0010]
In the method for producing an artificial stone material according to the first invention, the pattern display material is 24 to 26 parts by weight of an unsaturated polyester resin, 0.1 to 1 part by weight of a curing agent, and 100% by weight with respect to 100 parts by weight of aluminum hydroxide. It is preferable to use synthetic grains formed by curing and crushing a mixture containing 0.1 to 0.4 parts by weight of an accelerator and a small amount of a color pigment for polyester.
As synthetic grains, those having a size of 0.5 to 3 mm can be used. By using synthetic grains, an artificial stone material having a grain can be adjusted. Here, when the unsaturated polyester resin is added in an amount exceeding 26 parts by weight, the specific gravity of the synthetic grains decreases, and the synthetic grains float on the upper surface in the base compound injected into the mold. Moreover, when unsaturated polyester resin is added so that it may become less than 24 weight part, the specific gravity of a synthetic grain will become large and a synthetic grain will sink to the bottom within a formwork. Therefore, the unsaturated polyester resin is defined as 24-26 parts by weight with respect to 100 parts by weight of aluminum hydroxide, the specific gravity of the synthetic grains is adjusted, and the synthetic grains are not unevenly present in the base material.
The amount of the color pigment is preferably 0.01 to 0.4 parts by weight with respect to 100 parts by weight of the unsaturated polyester resin. In order to give the optimum color to the synthetic grains, it is difficult for the usage fee to be less than 0.01 parts by weight to contrast with the base material, and if it exceeds 0.4 parts by weight, the contrast with the base material becomes excessive. It is not preferable.
As the curing agent, an organic peroxide-based curing agent such as methyl ethyl ketone peroxide having a concentration of 55% can be used. Moreover, as a hardening accelerator which accelerates | stimulates hardening, 1% concentration cobalt naphthenate can be used, for example. The amount of the curing agent and the curing accelerator to be added varies depending on the types of the curing agent and the curing accelerator, but 0.1 to 1 part by weight of the curing agent and 0.1 to 0 part of the curing accelerator with respect to 24 to 26 parts by weight of the unsaturated polyester. If it is in the range of 1 to 0.4 parts by weight, the unsaturated polyester resin can be cured while ensuring sufficient pot life throughout the summer and winter.
The amount of synthetic grains added to the base material is adjusted each time according to the requirements of the stone to be produced. Curing of the mixture of aluminum hydroxide, unsaturated polyester resin, and coloring pigment is performed at room temperature curing (for example, 15 to 30 ° C. for 4 to 15 hours) and heat curing (for example, in an atmosphere of 80 to 85 ° C. 3 (4 hours) Any method may be used.
[0011]
The method for producing an artificial stone material according to the second invention in accordance with the above object is based on 150 to 300 parts by weight of fine inorganic filler and 0.4 to 3.8 parts by weight of a curing agent with respect to 100 parts by weight of unsaturated polyester resin. A first step of producing a base material having an appropriate fluidity by defoaming while stirring and mixing a curing accelerator of 0.4 to 1.3 parts by weight and a small amount of a color pigment in a mixer; While adding 0.4 to 3.8 parts by weight of a curing agent, 0.4 to 1.3 parts by weight of a curing accelerator, and a predetermined amount of a color pigment to 100 parts by weight of an unsaturated polyester resin, stirring and mixing uniformly. A second step of adjusting the flowable pattern material that defoams and forms an onyx pattern, and the flowable pattern material is added at a ratio of 0.02 to 1 part by weight with respect to 100 parts by weight of the base material. A base compound in which the fluid picture material is dispersed in a striped pattern in the base material. A third step of forming a mold, a fourth step of injecting the base compound into a mold and curing at room temperature to form a primary cured body, and removing the primary cured body from the mold to form a heat treatment apparatus. And a fifth step of heat-curing and making an artificial stone.
[0012]
As the highly viscous unsaturated polyester resin used for the flowable pattern material, for example, one having a viscosity of 1500 to 2000 millipascal seconds can be used. Further, the color and amount of the color pigment are adjusted each time according to the requirements of the stone to be produced. 0.02 to 1 part by weight of a fluid pattern material is added to 100 parts by weight of a base material that has been adjusted in advance, and, for example, each of several arbitrary locations in the container is stirred for several seconds with a manual stirrer. The viscosity of the flowable picture material is 3 to 4 times larger than the viscosity of the base material, so that the base compound can be brought into an inhomogeneous mixed state by simply stirring several arbitrary locations for several seconds each with a manual stirrer. Of course, the fluid picture material added to the base material is mixed in a striped pattern. Therefore, the dispersion form of the flowable pattern material in the mold can be controlled by changing the size of the spout and the injection speed when the base compound is injected into the mold. For example, when the injection speed is low, the stripe pattern interval is wide, and when the injection speed is high, the stripe pattern interval is narrow. Since the flowable picture material present in a striped pattern in the mold has a higher viscosity than the base compound, it does not mix with each other. By performing the curing process in this state, the striped fluid pattern material can be cured and fixed in the base compound.
[0013]
In the manufacturing method of artificial stone materials according to the first and second inventions, when the base material is made in the first step, 0.5 to 2 parts by weight of an antifoaming agent is used with respect to 100 parts by weight of the base material. It is preferable to add.
Add 0.5 to 2 parts by weight of antifoaming agent to add unsaturated polyester resin, finely divided inorganic filler, coloring pigment, curing agent, curing accelerator, and pattern display material (or flowable pattern material) Thus, the air entrained during mixing can be efficiently removed in a short time. Here, as an antifoamer, the commercially available antifoamer for polyester can be used.
[0014]
An artificial stone material joining method according to an embodiment of the present invention that meets the above-described object is a method of defoaming while stirring and mixing an unsaturated polyester resin, a fine inorganic filler, a curing agent, a curing accelerator, and a small amount of a color pigment. A base compound prepared by mixing a base material prepared by performing a predetermined amount of granular pattern display material forming a stone-like pattern, or a predetermined amount of flowable pattern material forming an onyx-like pattern, A method for joining an artificial stone obtained by injecting into a mold and curing at room temperature, then demolding from the mold and heat-curing, to 100 parts by weight of unsaturated polyester resin having high viscosity and thixotropy 120 to 150 parts by weight of the same inorganic filler as the finely divided inorganic filler used in the artificial stone material, 0.4 to 3.8 parts by weight of the curing agent, 0.4 to 1.3 parts by weight of the curing accelerator, and Used for the artificial stone Add a small amount of the same color pigment as the color pigment, and defoaming while stirring and mixing in a mixer to produce an adhesive, and the adhesion in the gap provided between the artificial stone materials to be bonded to each other A second step of filling the adhesive, and curing the filled adhesive with the gap maintained at a predetermined interval; and a third step of polishing and removing the cured adhesive that has adhered to the surface of the artificial stone. .
[0015]
Since an unsaturated polyester resin with high viscosity and thixotropy is used for the adhesive, the necessary amount of adhesive can be applied to the gaps between the artificial stone by filling and extruding the adhesive supply device such as a squeezer. Can be filled. In addition, since the extruded adhesive does not flow unless external force is applied because it has thixotropic properties, the gap filled with the adhesive is held at a predetermined interval, and the gap is kept in the gap portion until the adhesive starts to harden. The adhesive can be securely fixed. Note that by bringing the composition of the adhesive closer to the composition of the artificial stone material to be joined, the hardened joining layer becomes a structure close to the base material of the artificial stone material, and the joining boundary becomes inconspicuous. For this reason, 120 to 150 parts by weight of the same inorganic filler as the finely divided inorganic filler used for the artificial stone is used for 100 parts by weight of the unsaturated polyester resin having high viscosity and thixotropy, and the curing agent is 0 parts. .About.3.8 to 3.8 parts by weight, 0.4 to 1.3 parts by weight of the accelerator, and a small amount of the same color pigment as that used for the artificial stone material. When the inorganic filler is less than 120 parts by weight, a structure close to the base material of the artificial stone cannot be obtained, and when the inorganic filler is used in excess of 150 parts by weight, the adhesion with the artificial stone is lowered. Therefore, the usage fee for the inorganic filler is defined as 120 to 150 parts by weight.
[0016]
DETAILED DESCRIPTION OF THE INVENTION
Next, embodiments of the present invention will be described with reference to the accompanying drawings for understanding of the present invention.
FIG. 1 is a cross-sectional view showing a state in which a base compound is injected into a mold by the method for manufacturing an artificial stone material according to the first embodiment of the present invention, and FIG. 2 shows a second embodiment of the present invention. Sectional drawing which shows the state which injected the base compound into the formwork with the manufacturing method of the artificial stone which concerns, FIG. 3 is the state which injected the base compound into the formwork with the manufacturing method of the artificial stone which concerns on the 3rd Embodiment of this invention 4 (a), 4 (b), and 4 (c) are cross sections of artificial stone materials manufactured by applying the artificial stone material manufacturing methods according to the first to third embodiments of the present invention, respectively. FIG. 5 is a cross-sectional view showing an arrangement before joining artificial stones to which the method for joining artificial stones according to one embodiment of the present invention is applied, and FIG. 6 shows joining of artificial stones to which the joining method for artificial stones is applied. It is sectional drawing explaining the state of time.
[0017]
The manufacturing method of the artificial stone material which concerns on the 1st Embodiment of this invention is demonstrated in detail. 100 parts by weight of an unsaturated polyester resin having a viscosity of about 500 millipascal seconds, 150 to 300 parts by weight of aluminum hydroxide having a particle size of 100 μm or less and a whiteness of 96 or more, which is an example of an inorganic filler, to adjust the color to be expressed 0.04 to 1.3 parts by weight of a color pigment, 0.4 to 3.8 parts by weight (preferably 0.4 to 3.0 parts by weight) of methyl ethyl ketone 55% having a concentration of 55% as an example of a curing agent, curing The base material 11 containing 0.4 to 1.3 parts by weight (preferably 0.4 to 1.0 parts by weight) of 1% -concentration cobalt naphthenate, which is an example of an accelerator, is commercially available as an example of an antifoaming agent. The defoaming agent for polyester was added at a ratio of 0.5 to 2 parts by weight with respect to 100 parts by weight of the base material 11, and colored scale-like alumina oxide having a scale size of 0.5 to 3 mm as a pattern display material Aiming at system pattern display material 12 In addition quantity capable pebble tone representation that, in an example of a mixing machine rotating mixer, for example by performing a defoaming while stirring and mixed for 10 minutes, base compound to adjust (or, first step).
[0018]
As shown in FIG. 1, a base compound having an appropriate fluidity is adjusted and poured into a mold 21 coated with a commercially available wax-based mold release agent, and left at room temperature for 4 to 15 hours to be cured and removed. The first cured body 22 is obtained by molding (the second step). Here, as the mold 21, for example, a bottom plate portion 23 made of any one of granite, tempered glass, and stainless steel plate on a flat surface and a stainless steel square steel tube 24 on the side portion can be assembled and disassembled. Can be used. The primary hardened body 22 is removed from the mold 21 and placed in an air bath which is an example of a heat treatment apparatus, and is heated and cured at a temperature of 80 to 85 ° C. for 3 to 4 hours (third process). Manufacturing.
[0019]
As shown in FIG. 4 (a), an artificial stone material 10 to which the method for manufacturing an artificial stone material according to the first embodiment of the present invention is applied includes a base material 11 that forms a matrix of the artificial stone material 10, and a base material 11 It has the colored scale-like alumina oxide type | system | group pattern display material 12 disperse | distributed in it. Since it is the scale-like alumina oxide pattern display material 12, the scale-like alumina oxide pattern display material 12 has various directions with respect to the surface 13 of the artificial stone material 10 depending on the situation when poured into the mold 21. Turn to. For example, when the bottom surface of the scale-like alumina oxide pattern display material 12 is arranged along the surface 13 of the artificial stone material 10, the scale portion of the scale-like alumina oxide pattern display material 12 is exposed, and the scale-like alumina oxide pattern is displayed. If it arrange | positions so that the thickness part of the exposed material 12 may follow the surface 13 of the artificial stone material 10, the thickness part of the scale-like alumina oxide pattern exposed material 12 will express. For this reason, various stone-like structures can be formed. In addition, since the base material 11 has translucency, the scale-like alumina oxide type | system | group pattern display material 12 currently disperse | distributed inside can also be seen through from the surface 13, and can express a feeling of depth and heavy texture. it can.
[0020]
Next, the manufacturing method of the artificial stone material which concerns on the 2nd Embodiment of this invention is demonstrated in detail.
First, the adjustment method of the synthetic grain 16 as a pattern display material is demonstrated. 24 to 26 parts by weight of an unsaturated polyester resin having a viscosity of about 500 millipascal seconds with respect to 100 parts by weight of aluminum hydroxide, and 0.1 to 1 weight of 55% -concentrated methyl peroxy ketone as an example of a curing agent Rotating by adding 0.1 to 0.4 parts by weight of 1% -concentrated cobalt naphthenate, which is an example of a curing accelerator, and 0.01 to 0.4 parts by weight of a color pigment for adjusting the hue to be expressed For example, the mixture is prepared by mixing with a mold mixer for 10 minutes, for example, and is molded into a foil shape having a thickness of 5 to 10 mm, for example, and left to cure at room temperature for 4 to 15 hours. The hardened plate is crushed with a crusher to obtain a particle size of 0.5 to 3 mm, thereby producing a synthetic grain 16.
[0021]
100 parts by weight of an unsaturated polyester resin having a viscosity of about 500 millipascal seconds, 150 to 300 parts by weight of aluminum hydroxide having a particle size of 100 μm or less and a whiteness of 96 or more, which is an example of an inorganic filler, to adjust the color to be expressed 0.04 to 1.3 parts by weight of a color pigment, 0.4 to 3.8 parts by weight (preferably 0.4 to 3.0 parts by weight) of methyl ethyl ketone 55% having a concentration of 55% as an example of a curing agent, curing Commercially available as an example of an antifoaming agent in the base material 15 containing 0.4 to 1.3 parts by weight (preferably 0.4 to 1.0 parts by weight) of cobalt naphthenate having a concentration of 1%, which is an example of an accelerator. The antifoaming agent for polyester is added at a ratio of 0.5 to 2 parts by weight with respect to 100 parts by weight of the base material 15, and the produced synthetic grain 16 is added in an amount capable of expressing the target grain tone, and rotated. 10 minutes in a mold mixer And 拌 mixed to prepare a base compound (the above first process). As shown in FIG. 2, the prepared base compound is poured into a mold 21 coated with a commercially available wax-based mold release agent, left to stand at room temperature for 4 to 15 hours, and then demolded to be a primary cured body 25. Is obtained (the second step). The primary hardened body 25 is removed from the mold 21 and placed in an air bath which is an example of a heat treatment apparatus, and is heated and cured at a temperature of 80 to 85 ° C. for 3 to 4 hours (third process). Manufacturing.
[0022]
As shown in FIG. 4B, the artificial stone material 14 to which the artificial stone manufacturing method according to the second embodiment of the present invention is applied includes a base material 15 that forms a matrix of the artificial stone material 14, and a base material 15 And synthetic grains 16 dispersed therein. Since the synthetic grains 16 have a crushed shape, any synthetic grains 16 can be clearly exposed on each surface 17 of the artificial stone material 14. In addition, since the base material 15 has translucency, the synthetic grains 16 dispersed inside can also be seen through the surface 17 and can express a sense of depth and heavy texture.
[0023]
Then, the manufacturing method of the artificial stone material which concerns on the 3rd Embodiment of this invention is demonstrated in detail.
100 parts by weight of an unsaturated polyester resin having a viscosity of about 500 millipascal seconds, 150 to 300 parts by weight of aluminum hydroxide having a particle size of 100 μm or less and a whiteness of 96 or more, which is an example of an inorganic filler, to adjust the color to be expressed 0.04 to 1.3 parts by weight of a color pigment, 0.4 to 3.8 parts by weight (preferably 0.4 to 3.0 parts by weight) of methyl ethyl ketone 55% having a concentration of 55% as an example of a curing agent, curing The base material 19 containing 0.4 to 1.3 parts by weight (preferably 0.4 to 1.0 parts by weight) of 1% -concentration cobalt naphthenate, which is an example of an accelerator, is commercially available as an example of an antifoaming agent. The antifoaming agent for polyester was added at a ratio of 0.5 to 2 parts by weight with respect to 100 parts by weight of the base material 19 and defoamed with a rotary mixer, for example, while stirring and mixing for 10 minutes. (First step . Further, 0.4% to 3.8 parts by weight of 55% concentration methyl ethyl ketone 55% as an example of a curing agent with respect to 100 parts by weight of highly viscous unsaturated polyester resin having a viscosity of about 1500 to 2000 millipascal seconds (preferably 0.4 to 3.0 parts by weight), 1% concentration cobalt naphthenate 0.4 to 1.3 parts by weight (preferably 0.4 to 1.0 parts by weight), which is an example of a curing accelerator, and expression A flowable picture material 26 is prepared by adding a color pigment for polyester for adjusting a desired hue and defoaming with a rotary mixer, for example, while stirring and mixing uniformly for 20 minutes (the second step).
[0024]
Next, with respect to 100 parts by weight of the base material 19, the prepared fluid picture material 26 having a viscosity of, for example, about 90 g / cms is added at a rate of 0.02 to 1 part by weight, and the container is placed with a manual stirrer, for example. Fluidity picture material added to base material 19 after stirring for a few seconds each 26 A base compound in a state of being mixed in a stripe pattern is manufactured (the third step). As shown in FIG. 3, the obtained base compound is injected into the mold 21. At this time, the injection is performed while arbitrarily adjusting the diameter of the spout at the time of injecting the base compound into the mold 21 and further changing the injection speed. As a result, the interval and thickness of the stripe pattern formed by the fluid picture material 26 can be adjusted. Since the fluid picture material 26 present in a striped pattern in the mold 21 has a higher viscosity than the base material 19, it does not mix with each other and has a striped pattern formed when injected. The state is maintained as it is. Accordingly, when left in this state at room temperature for 4 to 15 hours to be cured and demolded, the primary cured body 27 in which the striped pattern formed when injected is exposed is obtained (the fourth step). The primary hardened body 27 is removed from the mold 21 and placed in an air bath which is an example of a heat treatment apparatus, and is heated and cured at a temperature of 80 to 85 ° C. for 3 to 4 hours (fifth step). Manufacturing.
[0025]
As shown in FIG. 4C, the artificial stone 18 to which the artificial stone manufacturing method according to the third embodiment of the present invention is applied includes a base material 19 that forms a matrix of the artificial stone 18 and a base material 19. The fluid pattern material 26 mixed therein has a striped portion 20 formed by curing a striped pattern portion formed when the pattern material 21 is poured into the mold 21. Since the striped portion 20 is formed in a complicated manner in the matrix and the matrix has translucency, the onyx-like artificial stone material 18 having a very deep three-dimensional and heavy texture is manufactured. Can do.
[0026]
A method for joining artificial stone materials according to an embodiment of the present invention will be described in detail. Here, the method for joining the artificial stone material according to the present embodiment is composed of adjustment of the adhesive 32 (see FIG. 6) used for joining and joining operation for joining the artificial stone material 10 with the adhesive 32. The adjustment will be described in detail separately for the adjustment of the adhesive 32 and the joining operation. The adhesive 32 was adjusted as follows. For example, 120 to 150 parts by weight of the same inorganic filler as the finely divided inorganic filler used for the artificial stone with respect to 100 parts by weight of the unsaturated polyester resin having a high viscosity of about 1500 to 2000 centipoise and having thixotropy, 0.04 to 1.3 parts by weight of the same color pigment as the color pigment used for the stone, and 0.4 to 3.8 parts by weight of methyl ethyl ketone peroxide 55% as an example of a curing agent (preferably 0.4 to 3.0 parts by weight), and 0.4 to 1.3 parts by weight (preferably 0.4 to 1.0 parts by weight) of 1% cobalt naphthenate, which is an example of a curing accelerator, is an example of a mixer. For example, it is produced by performing defoaming with a rotary mixer while stirring and mixing for 20 minutes (first step). For complete defoaming, an operation may be added in which the adjusted adhesive is placed in a container, placed on a vibration table and vibrated, and bubbles inside are lifted to the surface and removed.
[0027]
The joining operation was performed as follows. First, a yarn surface 29 is formed by lightly grinding, for example, with a # 320 paper file at a corner portion of the joint surface 28 of the artificial stone 10 manufactured by applying the method for manufacturing an artificial stone according to the embodiment. Next, the joint surface 28 and dirt in the vicinity of the joint surface 28 are removed with an organic solvent such as lacquer thinner. Furthermore, a block-shaped clamp fixing jig 30 made of, for example, a steel piece is dotted on one surface of the artificial stone material 10 with, for example, an instantaneous adhesive. The artificial stone material 10 is placed on a flat joining table 31 with the surface to which the clamp fixing jig 30 is bonded as the upper surface so that the interval between the joint surfaces 28 of the artificial stone material 10 is 2 to 3 mm, for example. .
The adhesive 32 filled in a supply device such as a squeezer is filled in gaps provided between the joint surfaces 28 of the artificial stone material 10. After the adhesive 32 is filled, clamps 33 are attached between the clamp fixing jigs 30 and tightened until the gap becomes, for example, 0.5 to 1 mm. By reducing the space between the joint surfaces 28 of the artificial stone material 10, the familiarity between the joint surface 28 of the artificial stone material 28 and the adhesive 32 can be improved. By reducing the gap, excess adhesive 32 flows out to the upper surface side. In this state, it is allowed to stand at room temperature for 4 to 15 hours to be cured. In addition, hardening can also be performed by hold | maintaining in the heated atmosphere of 40-50 degreeC for 1-4 hours (2nd process). After the curing is completed, the adhesive 32 that has flowed to the surface and hardened is polished and removed (third step).
[0028]
As mentioned above, although embodiment of this invention was described, this invention is not limited to this embodiment, For example, although aluminum hydroxide was used as a fine powder inorganic filler, calcium carbonate, talc, It is also possible to use cold water stones. As the antifoaming agent, a commercially available antifoaming agent for polyester is used, but it is also possible to use a combination of commercially available foam-breaking surfactants not containing silicone. Further, when defoaming by adding an antifoaming agent, the defoaming treatment can be performed more effectively by stirring and mixing under reduced pressure.
[0029]
【The invention's effect】
Claim 1 and dependent claims 3 In the manufacturing method of the artificial stone described, a predetermined amount of granular material that forms a stone-like pattern on a base material containing an unsaturated polyester resin, a finely divided inorganic filler, a curing agent, a curing accelerator, and a small amount of a coloring pigment. The first step of adding a pattern display material, defoaming while stirring and mixing in a mixer to make a base compound with appropriate fluidity, and injecting the base compound into the mold and curing it at room temperature to make the primary Since it has a second step of forming a hardened body and a third step of removing the primary hardened body from the mold and inserting it into a heat treatment apparatus to heat and harden it into an artificial stone material, a non-gel coating method of casting method Therefore, it is possible to produce an artificial stone material having high strength, excellent surface aesthetics, and easy post-processing.
[0030]
Also this In the artificial stone manufacturing method, colored scale-like alumina oxide pattern display material is used as the pattern display material, so the size of artificial stone materials with various pattern patterns such as single color, marble, and stone tone is limited. It can be manufactured without.
[0031]
[0032]
Claim 2 And the dependent claims 3 In the manufacturing method of the artificial stone described in the above, defoaming is performed while stirring and mixing an unsaturated polyester resin, a finely divided inorganic filler, a curing agent, a curing accelerator, and a small amount of a coloring pigment in a mixer. A first step of producing a base material having a high viscosity unsaturated polyester resin, a curing agent, a curing accelerator, and a predetermined amount of a coloring pigment, and defoaming while stirring and mixing uniformly to form an onyx pattern In the second step of adjusting the flowable pattern material, the flowable pattern material is added in a ratio of 0.02 to 1 part by weight with respect to 100 parts by weight of the base material, and the flowable pattern material is striped in the matrix. A third step of producing a dispersed base compound, a fourth step of injecting the base compound into the mold and curing it at room temperature to form a primary cured body, and removing the primary cured body from the mold to perform heat treatment. And heat harden to make artificial stone Because and a fifth step, very steric Onyx tone artificial stone with depth can be easily manufactured.
[0033]
In particular, the claims 3 In the manufacturing method of the artificial stone described, when the base material is made in the first step, 0.5 to 2 parts by weight of the antifoaming agent is added to 100 parts by weight of the base material, so that defoaming is sufficiently performed. Thus, it is possible to produce an artificial stone material that is uniform up to the inside. For this reason, the work of filling the pinholes appearing on the cut surface is eliminated, the processing time can be shortened, and the manufacturing cost can be reduced.
[0034]
Claim 4 In the method for joining artificial stone materials described above, high-viscosity unsaturated polyester resin having thixotropic properties, the same inorganic filler as the fine inorganic filler used for artificial stone materials, curing agents, curing accelerators, and artificial stone materials Add a small amount of the same color pigment as the used color pigment, and defoaming while stirring and mixing with a mixer to produce an adhesive and adhere to the gap provided between the artificial stone materials to be joined to each other A second step of curing the adhesive filled with an agent and holding the gap at a predetermined interval, and a third step of polishing and removing the cured adhesive that adheres to the surface of the artificial stone. Can be difficult to identify, and it is easy to make complex deformed artificial stone by joining artificial stone manufactured using existing formwork without using special formwork. And cheap to manufacture Theft is possible.
[Brief description of the drawings]
FIG. 1 is a cross-sectional view showing a state in which a base compound is injected into a mold by a method for manufacturing an artificial stone material according to a first embodiment of the present invention.
FIG. 2 is a cross-sectional view showing a state in which a base compound is injected into a mold by the artificial stone manufacturing method according to the second embodiment of the present invention.
FIG. 3 is a perspective sectional view showing a state in which a base compound is injected into a mold by the artificial stone manufacturing method according to the third embodiment of the present invention.
FIGS. 4A, 4B, and 4C are cross-sectional views of artificial stone materials manufactured by applying the artificial stone material manufacturing methods according to the first to third embodiments of the present invention, respectively.
FIG. 5 is a cross-sectional view showing an arrangement before joining artificial stones to which an artificial stone joining method according to an embodiment of the present invention is applied.
FIG. 6 is a cross-sectional view illustrating a state at the time of joining an artificial stone material to which the artificial stone joining method is applied.
[Explanation of symbols]
10: Artificial stone material, 11: Base material, 12: Scale-like alumina oxide pattern display material, 13: Surface, 14: Artificial stone material, 15: Base material, 16: Synthetic grain, 17: Surface, 18: Artificial stone material, 19: Base material, 20: Striped part, 21: Formwork, 22: Primary hardened body, 23: Bottom plate part, 24: Stainless steel square tube, 25: Primary hardened body, 26: Fluid pattern material, 27: Primary cured body, 28: joining surface, 29: thread surface, 30: clamp fixing jig, 31: joining base, 32: adhesive, 33: clamp

Claims

With respect to 100 parts by weight of unsaturated polyester resin, 150 to 300 parts by weight of fine inorganic filler, 0.4 to 3.8 parts by weight of curing agent, 0.4 to 1.3 parts by weight of curing accelerator, and a small amount The base material containing the color pigment is added with a predetermined amount of granular pattern display material that forms a stone-like pattern, and defoamed while stirring and mixing with a mixer to make a base compound having appropriate fluidity. 1 process,
A second step of injecting the base compound into a mold and curing at room temperature to form a primary cured body;
Have a third step of the artificial stone was cured by heating in charged into a demolding heat treatment apparatus from the mold the primary cured product,
Moreover, a colored scale-like alumina oxide pattern display material is used as the pattern display material .

With respect to 100 parts by weight of unsaturated polyester resin, 150 to 300 parts by weight of fine inorganic filler, 0.4 to 3.8 parts by weight of curing agent, 0.4 to 1.3 parts by weight of curing accelerator, and a small amount A first step of defoaming a colored pigment while stirring and mixing with a mixer to produce a base material having appropriate fluidity;
To 100 parts by weight of highly viscous unsaturated polyester resin, 0.4 to 3.8 parts by weight of curing agent, 0.4 to 1.3 parts by weight of curing accelerator, and a predetermined amount of coloring pigment are added and stirred uniformly. Defoaming while mixing, the second step of adjusting the flowable pattern material that forms the onyx-like pattern,
The flowable picture material is added in a ratio of 0.02 to 1 part by weight with respect to 100 parts by weight of the base material to form a base compound in which the flowable picture material is dispersed in the base material in a striped pattern. 3 steps,
A fourth step of injecting the base compound into a mold and curing at room temperature to form a primary cured body;
A method for producing an artificial stone material, comprising: a fifth step of removing the primary hardened body from the mold, inserting it into a heat treatment apparatus, and heat-curing it into an artificial stone material.

In the manufacturing method of the artificial stone material of Claim 1 or 2 , When making the said base material at a said 1st process, adding 0.5-2 weight part of antifoaming agents with respect to 100 weight part of this base material. A method for producing artificial stone.

Predetermined amount of granular material that forms a stone-like pattern on the base material prepared by defoaming while stirring and mixing unsaturated polyester resin, finely divided inorganic filler, curing agent, curing accelerator, and a small amount of colored pigment A base compound prepared by mixing a predetermined amount of fluid pattern material that forms an onyx pattern is injected into the mold, cured at room temperature, and then removed from the mold and heat-cured. A method of joining artificial stones obtained by
120 to 150 parts by weight of the same inorganic filler as the finely divided inorganic filler used in the artificial stone material and 100 to 150 parts by weight of the unsaturated polyester resin having high thixotropic properties and a curing agent of 0.4 to 3.8 Add an amount of parts by weight, 0.4 to 1.3 parts by weight of a curing accelerator, and a small amount of the same color pigment as that used in the artificial stone, and defoaming while mixing with a mixer to produce an adhesive A first step of
A second step of filling the adhesive in a gap provided between the artificial stone materials to be bonded to each other, and curing the filled adhesive while holding the gap at a predetermined interval;
And a third step of polishing and removing the adhesive that has adhered to and hardened on the surface of the artificial stone material.