JP3700647B2 - Manufacturing method of artificial marble - Google Patents
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- JP3700647B2 JP3700647B2 JP2001392108A JP2001392108A JP3700647B2 JP 3700647 B2 JP3700647 B2 JP 3700647B2 JP 2001392108 A JP2001392108 A JP 2001392108A JP 2001392108 A JP2001392108 A JP 2001392108A JP 3700647 B2 JP3700647 B2 JP 3700647B2
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Description
【０００１】
【発明の属する技術分野】
本発明は、家具の部材や建材として用いられる人造大理石製造方法に関するものである。
【０００２】
【従来の技術】
従来から、熱硬化性樹脂と充填剤、柄材、補強材、内部離型剤、硬化剤などの添加物を配合した人造大理石成形用樹脂組成物を所望の注型金型に注入し、加熱硬化させることによって人造大理石を形成することが知られている。
【０００３】
人造大理石を製造するための原料となる熱硬化性樹脂としては、従来よりポリエステル樹脂、ビニルエステル樹脂、アクリル樹脂などが用いられている。これらを活用した人造大理石の成形品は、洗面カウンター、キッチンカウンター、浴槽、洗面ボールなどに広く利用されている。
【０００４】
通常、高意匠柄やグラニット調柄の人造大理石製品を得るために形状や色調が異なる数種の柄材が配合された人造大理石成形用樹脂組成物を得ることが行われている。しかし、現状では、添加配合される柄材は色調が異なったり、粒径が異なったものの組み合わせ、即ち、色と粒径の変化だけの組み合わせで行われており、得られた柄材入りの人造大理石成形品はその柄模様が非常に単調で変化に乏しく、自然感や高級感あるいは高意匠性に欠けるという問題があった。
【０００５】
そこで、上記の従来例よりも高いデザイン性、自然感、高級感あるいは意匠性の高い人造大理石の製造方法が切望されているのが現状である。
【０００６】
【発明が解決しようとする課題】
本発明は上記の点に鑑みてなされたものであり、人造大理石形成用樹脂組成物に配合添加する人造大理石用の柄材に変化をつけたものを配合してコンパウンド化して成形硬化することで、より高いデザイン性、自然感、高級感あるいは意匠性の高いグラニット柄の人造大理石を得ることができ、また、製品強度を低下させることがない人造大理石の製造方法を提供することを課題とするものである。
【０００７】
【課題を解決するための手段】
上記課題を解決するために本発明に係る人造大理石の製造方法は、熱硬化性樹脂に充填剤、柄材、硬化剤などの添加物を配合した人造大理石成形用樹脂組成物を得て、この人造大理石成形用樹脂組成物を成形硬化させて人造大理石を製造する人造大理石の製造方法において、人造大理石成形用樹脂組成物に配合される人造大理石用の柄材を得るための人造大理石用の柄材組成物に添加配合される柄材として、別の柄材組成物に別の柄材を添加配合して成形硬化させ粉砕分級することを１回以上繰り返して得られた柄材を使用することを特徴とするものである。このように、人造大理石成形用樹脂組成物に配合される人造大 理石用の柄材を得るための人造大理石用の柄材組成物に添加配合される柄材として、別の柄材組成物に別の柄材を添加配合して成形硬化させ粉砕分級することを１回以上繰り返して得られた柄材を使用するため、人造大理石成形用樹脂組成物を成形硬化して得た人造大理石はより高いデザイン性、自然感、高級感あるいは意匠性の高いグラニット柄とすることができるものであり、また、人造大理石用の柄材中に混入している別の１種類以上の柄材を得るに当たって、人造大理石用の柄材を得るのと同様の工程を１回以上繰り返すことで簡単に得ることができるものである。
【０００８】
【発明の実施の形態】
以下、本発明を添付図面に示す実施形態に基づいて説明する。
【０００９】
本発明の人造大理石の製造方法は、熱硬化性樹脂に充填剤、柄材、硬化剤などの添加物を配合した人造大理石成形用樹脂組成物を得て、この人造大理石成形用樹脂組成物を成形硬化させて人造大理石を製造するに当たって、人造大理石成形用樹脂組成物に配合される人造大理石用の柄材として、人造大理石用の柄材組成物に１種類以上の別の柄材を添加配合して成形硬化させたものを粉砕分級して得られた柄材を使用するものであり、更に、上記の人造大理石成形用樹脂組成物に配合される人造大理石用の柄材を得るための人造大理石用の柄材組成物に添加配合される柄材として、本発明においては、別の柄材組成物に別の柄材を添加配合して成形硬化させ粉砕分級することを１回以上繰り返して得られた柄材を使用するものである。このようにして得た１種類以上の別の柄材を添加配合して成形硬化させたものを粉砕分級して得られた人造大理石用の柄材を人造大理石用樹脂組成物に配合し、この人造大理石成形用樹脂組成物を所望の注型金型に注入して加熱硬化させることでグラニット調柄の人造大理石成形品を得るものである。
【００１０】
人造大理石成形用樹脂組成物に配合する人造大理石用の柄材に添加配合する１種類以上の柄材は図１に示すような流れで得られる。
【００１１】
まず、第１段階として、図１の（１）〜（４）に示すように、それぞれ着色剤が異なる（着色剤ａ、着色剤ｂ、着色剤ｃ、着色剤ｄ……）、すなわち色調の異なる柄材用樹脂組成物を板状あるいはシート状などの形状に成形硬化させ、これを粉砕してある一定の粒径の範囲に分級して柄材ａ、柄材ｂ、柄材ｃ、柄材ｄ……を得る。
【００１２】
次に、第２段階として図１の（５）〜（８）に示すように、これらの柄材ａ、柄材ｂ、柄材ｃ、柄材ｄ……を目的とする柄模様に合うように設定された配合量と着色剤との組み合わせ（例えば、着色剤Ａと柄材ａ、柄材ｃ、柄材ｄ……との組み合わせ、着色剤Ｂと柄材ａ、柄材ｂ、柄材ｃ、……との組み合わせ、着色剤Ｃと柄材ｂ、柄材ｃ、柄材ｄ……との組み合わせなどなど）で柄材用樹脂組成物を得て、更に、この柄材用樹脂組成物を前記と同様に板状あるいはシート状などの形状に成形硬化させ、粉砕してある一定の粒径の範囲に分級して次の柄材Ａ、柄材Ｂ、柄材Ｃ……を得る。
【００１３】
次に、第３段階として図１の（９）に示すように、これらの柄材Ａ、柄材Ｂ、柄材Ｃ……を１種類以上人造大理石用の柄材として用いて目的の柄模様に合うように設定された配合量と着色剤との組み合わせで、柄材入りの人造大理石成形用樹脂組成物を得る。
【００１４】
次に、第４段階として図１の（１０）〜（１２）に示すように、上記の柄材入りの人造
大理石成形用樹脂組成物を所望の注型金型に注入して加熱硬化させることによってグラニット調柄の人造大理石成形品を得るものである。
【００１５】
ここで、本発明においては上記（５）〜（８）の操作を複数回繰り返して、より柄材に変化を与える。即ち、（８）の柄材Ａ、柄材Ｂ、柄材Ｃ……が（５）の柄材の組み合わせの部分になって（５）〜（８）の操作が１回あるいはそれ以上順次繰り返されることになるものである。なお、図１においては（５）〜（８）の操作が１回あるいはそれ以上順次繰り返されることを省略している図面である。
【００１６】
また、１種類以上の人造大理石用の柄材は、着色剤の種類や添加量、樹脂と充填剤の種類や配合比、あるいは、上記（５）〜（８）の操作の繰り返し度合いなどによって、色調や、透明性、あるいは柄模様がそれぞれ一粒毎に異なった非常に変化に富んだものになる。図２に本発明のグラニット調柄の人造大理石成形品１の一例を示している。この図２において２は柄材Ａを示し、３は柄材Ｂを示し、４は柄材Ｃを示し、５は柄材Ｄを示し、６は柄材Ｅを示している。また、図３は人造大理石成形品中に配合された人造大理石用の柄材の一例（柄材Ａを例示している）を示しており、７は柄材ａを示し、８は柄材ｂを示し、９は柄材ｃを示し、１０は柄材ｄを示し、１１は柄材ｅを示している。
【００１７】
本発明においては、この変化のある人造大理石用の柄材の平均厚みを０．１〜５．０ｍｍ、平均粒径を１．０ｍｍ以上とするものである。
【００１８】
ここで、平均厚みが０．１ｍｍ以下になると、薄くなりすぎて人造大理石用の柄材同士のくっつきがひどくなって人造大理石成形用樹脂組成物中での人造大理石用の柄材の分散性が極端に悪くなって目的とする柄表現が得られないばかりか製品強度の低下を招く結果となって好ましくない。一方、平均厚みが５．０ｍｍを越えると、人造大理石用の柄材同士のくっつきはないが、分散性が悪くなって上記と同様に製品強度の低下に影響を及ぼしてくるので好ましくない。また、平均粒径を１．０ｍｍ以上とするのは、１．０ｍｍ以上にならないとその変化に富んだ人造大理石用の柄材での表現が目立たないからである。つまり、平均粒径が１．０ｍｍ以下の人造大理石用の柄材では本発明の柄表現は得られない。
【００１９】
また、人造大理石用の柄材、あるいは人造大理石用の柄材中に配合される柄材の表面にあらかじめカップリング処理したものを用いると人造大理石用の柄材と樹脂、柄材と樹脂との密着性を向上できて、人造大理石製品の耐衝撃強度を向上させることができるものである。
【００２０】
また、人造大理石用の柄材の形状、あるいは人造大理石用の柄材中に配合される柄材の形状はその製造方法や粉砕条件によって粒形状（球形状）あるいは扁平形状のものが得られる。本発明においてはそれら単独、あるいは混合体の形で添加配合して用いることができるものである。
【００２１】
柄材、人造大理石用の柄材を構成する樹脂組成物の熱硬化性樹脂と、人造大理石用の柄材を添加して得られる人造大理石成形用樹脂組成物を構成する熱硬化性樹脂とは同じ種類のものを用いるのが好ましく、熱硬化性樹脂はポリエステル樹脂、ビニルエステル樹脂、アクリル樹脂の単独、あるいはこれらの２種類以上の混合系で用いることができる。
【００２２】
ポリエステル樹脂としては、熱硬化性のものとして無水マレイン酸のような不飽和二塩基酸および無水フタル酸のような飽和二塩基酸とグリコール類とを縮合反応させて合成され、分子内に不飽和結合とエステル結合を有するものである。また、通常、この樹脂には架橋剤としてスチレンモノマー、アクリルモノマー等が配合されていて、いわゆる不飽和ポリエステル樹脂と称されるものを用いるが、その形態は特に限定されるものではない。
【００２３】
ビニルエステル樹脂としては、ビスフェノール型ビニルエステル樹脂あるいはノボラック型ビニルエステル樹脂あるいはその両方を混合して用いることができる。
【００２４】
ここで、ビスフェノール型ビニルエステル樹脂は、ビスフェノール型エポキシ樹脂と酸との付加反応物であって、いずれも両末端のみに反応性不飽和基を有するものである。また、ビスフェノール型エポキシ樹脂としては、ビスフェノールＡ型、ビスフェノールＡＤ型、ビスフェノールＳ型、ビスフェノールＦ型等の各種のものを用いることができる。また、通常、このビニルエステル樹脂には架橋剤としてスチレンモノマー、アクリルモノマー等が配合されているものであるが、その形態は特に限定されるものではない。
【００２５】
アクリル樹脂としては、通常熱硬化型として、メチルメタアクリレートモノマー、あるいは多官能のアクリルモノマー、あるいはプレポリマー、あるいはポリマーのそれぞれ２種類以上の混合物で構成されたアクリルシロップと称されるものを用いるが、その形態は特に限定されるものではない。
【００２６】
また、ポリエステル樹脂、ビニルエステル樹脂、アクリル樹脂の２種類以上の混合系とする場合は、樹脂それぞれの特性及び充填剤との相互作用あるいは添加配合物との相互作用などにより目的とする製品品質に合った最適配合が求められるが、その配合量は特に限定されるものではない。
【００２７】
充填剤は、水酸化アルミニウム、シリカ、ガラスパウダーのうちの１種類、あるいは２種類以上の混合物として用いることができる。充填剤の配合量は、熱硬化性樹脂１００重量部に対して１００〜３００重量部とすることが好ましく、この範囲に満たないと、製品の耐衝撃強度は優れるが耐熱性を十分に発揮できないおそれがあり、また、この範囲を越えると耐熱性は優れるが耐衝撃強度が低下するおそれがある。しかし、特にこれを限定するものではない。
【００２８】
充填剤の粒径は小さいほど人造大理石製品の耐衝撃強度を向上させることができるが、樹脂組成物の粘度を急激に上昇させて製造が困難となる傾向になり、また、一方、充填剤の粒径が大きくなると、人造大理石成形用樹脂組成物の粘土は低下して製造での問題はなくなるが、人造大理石製品の耐衝撃強度が低下してしまう傾向になるため、平均粒径は５μｍ〜５０μｍ程度の範囲のものを用いるのが望ましい。しかし、これを特に限定するものではない。
【００２９】
また、充填剤の表面にあらかじめシランカップリング処理を施したものを用いると、その充填剤と樹脂との密着性を向上できて、人造大理石製品の耐衝撃強度を向上させることができるものである。
【００３０】
更に、人造大理石成形用樹脂組成物には硬化剤を配合する。
【００３１】
硬化剤としては、１，１，３，３−テトラメチルブチルパーオキシ−２−エチルヘキサノエートやｔ−ヘキシルパーオキシ−２−エチルヘキサノエート等を用いることができる。この硬化剤の配合割合は例えばビニルエステル樹脂の場合は、樹脂と架橋剤との総量１００重量部に対して０．５〜５重量部とするのが好ましいものである。
【００３２】
また、人造大理石成形用樹脂組成物には紫外線吸収剤、減粘剤、離型剤、ガラス繊維、着色剤を配合することもできる。
【００３３】
柄材用樹脂組成物あるいは人造大理石成形用樹脂組成物は、柄材あるいは人造大理石成形用柄材を含むこれらの配合物を所定の割合で配合し、撹拌機等により混合撹拌して配合調製する。
【００３４】
人造大理石成形用樹脂組成物から人造大理石を製造するに当たっては、その配合調製された人造大理石成形用樹脂組成物を２０〜５０Ｔｏｒｒ程度の減圧下で真空脱泡処理し、減圧状態から開放して成形硬化を待つ状態とする。
【００３５】
このようにして得られた柄材用樹脂組成物は板形状あるいはシート形状の成形型に注入し、また、人造大理石成形用樹脂組成物は所定形状の金型に注入し、これらの成形型あるいは金型を５０〜１１０℃の温度で３０〜１２０分間加熱する。
【００３６】
加熱することによりこれらの柄材用樹脂組成物あるいは人造大理石成形用樹脂組成物中の反応性不飽和基と、同じく樹脂中の重合性モノマーとの共重合反応を進行させて柄材用樹脂組成物あるいは人造大理石成形用樹脂組成物の硬化成形を行うものである。
【００３７】
上記のようにして得られた本発明の人造大理石用の柄材入りの人造大理石成形品は、人造大理石用の柄材そのものが色調や透明感あるいは柄模様が異なったもの、変化に富んだもので構成されているので、従来のものと比較してより高いデザイン性、自然感、高級感あるいは意匠性の高いグラニット柄の人造大理石を得ることができて、しかも、製品強度を低下させることがない人造大理石を得ることができるものである。
【００３８】
このような人造大理石の成形品は、洗面カウンター、キッチンカウンター、浴槽、洗面ボール、あるいは床材や家具の表面材等への商品化が容易となるものである。
【００３９】
【実施例】
以下、本発明を実施例により詳述する。
（実施例１）
熱硬化性樹脂として、ビニルエステル（昭和高分子（株）製 リポキシＲ−８０４）と、アクリルシロップ（三井化学（株）製 ＸＥ９２４−１）を９５／５の配合比で混合したものを用い、また充填剤として水酸化アルミニウム（昭和電工（株）製 Ｈ−３２０ 平均粒径１０μｍ）を用い、その配合比率を変え、それぞれに着色剤（トナー）を添加したもの（単位は重量部）、即ち、
（ａ）＝樹脂／充填剤／着色剤＝１００／９０／ブラウン色トナー０．４
（ｂ）＝樹脂／充填剤／着色剤＝１００／１２０／ベージュ色トナー０．３５
（ｃ）＝樹脂／充填剤／着色剤＝１００／１５０／白色トナー０．６
（ｄ）＝樹脂／充填剤／着色剤＝１００／１８０／黒色トナー０．２５
の４種類の柄材用樹脂組成物を調製した。更に、それぞれに硬化剤（日本油脂（株）製 パーキュアＨＯ）を３．０重量部づつ添加し、これを２０Ｔｏｒｒの減圧下で３０分間真空脱泡処理しながら撹拌混合した後、０．８ｍｍ厚みのシート状に成形する金型に注入し、金型温度を９５℃で３０分間加熱して硬化させ、クラッシャーで粉砕して分級し、図１の柄材ａ、柄材ｂ、柄材ｃ、柄材ｄを得た。次に、上記の（ａ）（ｂ）（ｃ）（単位は重量部）の柄材用樹脂組成物に
（Ａ）＝樹脂組成物（ａ）／柄材ｂ／柄材ｃ／柄材ｄ＝１００／３．５／２．５／１．５
（Ｂ）＝樹脂組成物（ｂ）／柄材ａ／柄材ｃ／柄材ｄ＝１００／３．０／２．０／１．０
（Ｃ）＝樹脂組成物（ｃ）／柄材ａ／柄材ｂ／柄材ｄ＝１００／２．５／５．５／２．５
の３種類の柄材用樹脂組成物を調製した。更に、それぞれに硬化剤（日本油脂（株）製 パーキュアＨＯ）を３．０重量部づつ添加し、これを２０Ｔｏｒｒの減圧下で６０分間真空脱泡処理しながら撹拌混合した後、それぞれを０．８５ｍｍ厚みのシート状に成形する金型に注入し、金型温度を９５℃で２５分間加熱して硬化させ、クラッシャーで粉砕して分級し、再び図１の柄材ａ、柄材ｂ、柄材ｃ、柄材ｄ＝柄材ａ’、柄材ｂ’、柄材ｃ’、柄材ｄ’を得た。
更に、上記の（ａ）（ｂ）（ｃ）（単位は重量部）の柄材用樹脂組成物に、
（Ａ）’＝樹脂組成物（ａ）／柄材ｂ’／柄材ｃ’／柄材ｄ’＝１００／２．５／１．５／１．５
（Ｂ）’＝樹脂組成物（ｂ）／柄材ａ’／柄材ｃ’／柄材ｄ’＝１００／２．５／１．０／２．０
（Ｃ）’＝樹脂組成物（ｃ）／柄材ａ’／柄材ｂ’／柄材ｄ’＝１００／３。０／４．０／３．０
の３種類の柄材用樹脂組成物を調製した。更に、それぞれに硬化剤（日本油脂（株）製 パーキュアＨＯ）を３．０重量部づつ添加し、これを２０Ｔｏｒｒの減圧下で６０分間真空脱泡処理しながら撹拌混合した後、それぞれを０．７ｍｍ厚みのシート状に成形する金型と５ｍｍ厚の板状に成形する金型に注入し、金型温度を９５℃で４０分間加熱して硬化させクラッシャーで粉砕して分級し、平均粒径が１．０〜４．０ｍｍの図１の柄材Ａ’、柄材Ｂ’、柄材Ｃ’、及び平均粒径が１．０〜５．０ｍｍの扁平状の柄材Ａ”、柄材Ｂ”、柄材Ｃ”を得た。
【００４０】
次に、上記（ａ）の柄材用樹脂組成物を人造大理石成形用樹脂組成物として用い、また、上記柄材Ａ’、柄材Ｂ’、柄材Ｃ’、柄材Ａ”、柄材Ｂ”、柄材Ｃ”を人造大理石用の柄材として用い、人造大理石成形用樹脂組成物として用いる（ａ）の柄材用樹脂組成物に柄材Ａ’＝１．５重量部、柄材Ｂ’＝３．５重量部、柄材Ｃ’＝１．０重量部、柄材Ａ”＝２．０重量部、柄材Ｂ”＝２．０重量部、柄材Ｃ”＝２．５重量部配合して人造大理石用の柄材入り人造大理石用樹脂組成物を調製した。更に、硬化剤（日本油脂（株）製 パーキュアＨＯ）を３．０重量部添加し、これを２０Ｔｏｒｒの減圧下で６０分間真空脱泡処理しながら撹拌混合した後、所定形状で１２ｍｍ厚みに設定された注型金型内に注入して金型温度を９５℃で１００分間加熱して硬化させ、図２のような形態をした多色の人造大理石用の柄材の入ったグラニット調柄の人造大理石成形品を得た。
【００４１】
【発明の効果】
上記のように本発明の請求項１記載の発明にあっては、人造大理石成形用樹脂組成物に配合される人造大理石用の柄材を得るための人造大理石用の柄材組成物に添加配合される柄材として、別の柄材組成物に別の柄材を添加配合して成形硬化させ粉砕分級することを１回以上繰り返して得られた柄材を使用するので、より高いデザイン性、自然感、高級感あるいは意匠性の高いグラニット柄となった人造大理石を製造することができるものであり、しかも、本発明においては、人造大理石成形用樹脂組成物に配合される人造大理石用の柄材を得るための人造大理石用の柄材組成物に添加配合される柄材として、別の柄材組成物に別の柄材を添加配合して成形硬化させ粉砕分級することを１回以上繰り返して得られた柄材を使用するので、人造大理石用の柄材中に混入している別の１種類以上の柄材を得るに当たって、人造大理石用の柄材を得るのと同様の工程を１回以上繰り返すことで簡単に得ることができるものである。
【図面の簡単な説明】
【図１】 本発明の人造大理石の製造方法の製造順序を示すフロー図である。
【図２】 本発明により得られた人造大理石成形品の一例を示す斜視図である。
【図３】 同上の人造大理石用の柄材の詳細を示す説明図である。
【符号の説明】
１ 人造大理石成形品[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a method for producing artificial marble used as a furniture member or building material.
[0002]
[Prior art]
Conventionally, an artificial marble molding resin composition containing a thermosetting resin and additives such as a filler, a pattern material, a reinforcing material, an internal mold release agent, and a curing agent is poured into a desired casting mold and heated. It is known to form artificial marble by curing.
[0003]
Conventionally, polyester resins, vinyl ester resins, acrylic resins, and the like have been used as thermosetting resins as raw materials for producing artificial marble. Artificial marble moldings utilizing these are widely used in wash counters, kitchen counters, bathtubs, wash bowls, etc.
[0004]
Usually, in order to obtain an artificial marble product having a high design pattern or a granite pattern, a resin composition for molding an artificial marble in which several types of pattern materials having different shapes and colors are blended is obtained. However, under the present circumstances, the pattern material to be added and blended is a combination of ones with different color tone or different particle sizes, that is, only combinations of changes in color and particle size, and the resulting artificial material containing the pattern material is used. The marble molded product has a problem that its pattern is very monotonous and hardly changes, and lacks a natural feeling, luxury or high design.
[0005]
Therefore, the present situation is that there is an urgent need for a method for producing artificial marble that has higher designability, naturalness, luxury, or design than the above-mentioned conventional examples.
[0006]
[Problems to be solved by the invention]
The present invention has been made in view of the above points, and by blending and adding a modified pattern material for artificial marble to be added to the resin composition for forming artificial marble, it is molded and cured. An object of the present invention is to provide a method for producing an artificial marble that can obtain a granite patterned artificial marble with higher design, naturalness, luxury or design, and that does not reduce product strength. Is.
[0007]
[Means for Solving the Problems]
In order to solve the above problems, a method for producing an artificial marble according to the present invention obtains a resin composition for molding an artificial marble in which additives such as a filler, a pattern material, and a curing agent are blended with a thermosetting resin. Artificial marble pattern for obtaining artificial marble pattern material blended in artificial marble molding resin composition in a method of producing artificial marble by molding and curing an artificial marble molding resin composition As a pattern material added and blended in the material composition, a pattern material obtained by repeatedly adding and blending another pattern material into another pattern material composition, molding and curing, and pulverizing and classifying it once or more is used. It is characterized by. Thus, as a pattern material to be added to and blended into the handle material composition for artificial marble to obtain the handle member for artificial Dali stone to be incorporated in the artificial marble molding resin composition, another handle material composition The artificial marble obtained by molding and curing the artificial marble molding resin composition is used in order to use a pattern material obtained by adding, blending, molding, curing, pulverizing and classifying another pattern material one or more times. higher design, natural feeling state, and are not able to luxury or design highly granite pattern, also, a different one or more of the handle material mixed in the handle member for artificial marble In obtaining it, it can be easily obtained by repeating the same process as that for obtaining a pattern material for artificial marble one or more times.
[0008]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, the present invention will be described based on embodiments shown in the accompanying drawings.
[0009]
The method for producing an artificial marble according to the present invention obtains a resin composition for molding an artificial marble in which additives such as a filler, a pattern material, and a curing agent are blended with a thermosetting resin, and the resin composition for molding an artificial marble is obtained. In producing artificial marble by molding and curing, as a pattern material for artificial marble to be blended in the resin composition for molding artificial marble, one or more other pattern materials are added to the pattern material composition for artificial marble. In order to obtain a pattern material for artificial marble to be blended with the above-mentioned resin composition for molding artificial marble, the pattern material obtained by pulverizing and classifying the molded and cured product is used. As a pattern material to be added and blended with the pattern material composition for marble, in the present invention, another pattern material is added to and blended with another pattern material composition, molded, cured, and pulverized and classified one or more times. The pattern material obtained is used. One or more different pattern materials obtained in this way were added and blended and molded and cured, and the pattern material for artificial marble obtained by pulverizing and classifying was blended into the resin composition for artificial marble. The artificial marble molding resin composition is poured into a desired casting mold and cured by heating to obtain a granite-patterned artificial marble molded product.
[0010]
One or more kinds of pattern materials added to and blended with the artificial marble pattern material to be blended with the artificial marble molding resin composition are obtained in the flow shown in FIG.
[0011]
First, as shown in FIGS. 1 (1) to (4), as the first stage, the colorants are different (colorant a, colorant b, colorant c, colorant d...), That is, the color tone. Different pattern material resin compositions are molded and cured into a plate shape or sheet shape, and are pulverized and classified into a certain range of particle diameters to obtain a pattern material a, a pattern material b, a pattern material c, and a pattern. Obtain material d ....
[0012]
Next, as shown in FIGS. 1 (5) to (8), the pattern material a, pattern material b, pattern material c, pattern material d,... Combination of colorant and colorant (for example, combination of colorant A with pattern material a, pattern material c, pattern material d..., Colorant B with pattern material a, pattern material b, pattern material a combination of c,..., a combination of a colorant C and a pattern material b, a pattern material c, a pattern material d, etc.) to obtain a resin composition for a pattern material. In the same manner as described above, the product is shaped and cured into a plate shape or a sheet shape, and pulverized and classified into a certain range of particle diameters to obtain the following pattern material A, pattern material B, pattern material C,. .
[0013]
Next, as shown in (9) of FIG. 1, as a third stage, the pattern material A, pattern material B, pattern material C,... Are used as a pattern material for artificial marble. A resin composition for molding an artificial marble containing a pattern material is obtained by a combination of the blending amount and the colorant set so as to match each other.
[0014]
Next, as shown in (10) to (12) of FIG. 1 as the fourth stage, the artificial marble molding resin composition containing the pattern material is poured into a desired casting mold and cured by heating. By this, an artificial marble molded product with a granite pattern is obtained.
[0015]
Here, in the present invention, the operations (5) to (8) are repeated a plurality of times to further change the pattern material . That is, the pattern material A, the pattern material B, the pattern material C in (8) becomes a combination part of the pattern material in (5), and the operations in (5) to (8) are repeated once or more sequentially. It will be. In FIG. 1, the operations (5) to (8) are omitted from being repeated once or more sequentially.
[0016]
Moreover, the pattern material for one or more types of artificial marble is, depending on the type and amount of the colorant, the type and blending ratio of the resin and filler, or the degree of repetition of the operations (5) to (8) above. The color tone, transparency, and pattern will be very varied with different grains. FIG. 2 shows an example of an artificial marble molded article 1 having a granite pattern according to the present invention. In FIG. 2, 2 indicates a pattern material A, 3 indicates a pattern material B, 4 indicates a pattern material C, 5 indicates a pattern material D, and 6 indicates a pattern material E. FIG. 3 shows an example of a pattern material for artificial marble (the pattern material A is illustrated) blended in the artificial marble molded product, 7 indicates the pattern material a, and 8 indicates the pattern material b. , 9 indicates the pattern material c, 10 indicates the pattern material d, and 11 indicates the pattern material e.
[0017]
In the present invention, the pattern material for artificial marble having this change has an average thickness of 0.1 to 5.0 mm and an average particle diameter of 1.0 mm or more.
[0018]
Here, when the average thickness becomes 0.1 mm or less, the pattern material for the artificial marble becomes too thin and the sticking between the pattern materials for the artificial marble becomes so severe that the dispersibility of the pattern material for the artificial marble in the resin composition for molding the artificial marble is increased. This is not preferable because it is extremely worse and the desired pattern expression cannot be obtained and the product strength is reduced. On the other hand, if the average thickness exceeds 5.0 mm, the pattern materials for artificial marble do not stick to each other, but the dispersibility is deteriorated and the product strength is lowered as described above, which is not preferable. The reason why the average particle size is 1.0 mm or more is that the expression with the pattern material for artificial marble, which is rich in changes, is not conspicuous unless it is 1.0 mm or more. That is, the pattern expression of the present invention cannot be obtained with a pattern material for artificial marble having an average particle size of 1.0 mm or less.
[0019]
In addition, if a pattern material for artificial marble or a surface of a pattern material mixed in the pattern material for artificial marble is pre-coupled, the pattern material and resin for artificial marble, and the pattern material and resin Adhesion can be improved and the impact strength of artificial marble products can be improved.
[0020]
Moreover, the shape of the pattern material for artificial marble or the shape of the pattern material blended in the pattern material for artificial marble can be obtained in a grain shape (spherical shape) or a flat shape depending on the manufacturing method and grinding conditions. In the present invention, they can be used alone or in combination in the form of a mixture.
[0021]
The thermosetting resin of the resin composition constituting the pattern material, the pattern material for artificial marble, and the thermosetting resin constituting the resin composition for molding the artificial marble obtained by adding the pattern material for artificial marble The same type is preferably used, and the thermosetting resin can be used alone or in combination of two or more of polyester resins, vinyl ester resins and acrylic resins.
[0022]
Polyester resins are thermosetting and synthesized by the condensation reaction of unsaturated dibasic acids such as maleic anhydride and saturated dibasic acids such as phthalic anhydride and glycols, and unsaturated in the molecule. It has a bond and an ester bond. Usually, this resin is blended with a styrene monomer, an acrylic monomer or the like as a cross-linking agent, and what is called an unsaturated polyester resin is used, but the form is not particularly limited.
[0023]
As the vinyl ester resin, a bisphenol type vinyl ester resin or a novolac type vinyl ester resin or a mixture of both can be used.
[0024]
Here, the bisphenol type vinyl ester resin is an addition reaction product of a bisphenol type epoxy resin and an acid, and both have reactive unsaturated groups only at both ends. As the bisphenol type epoxy resin, various types such as a bisphenol A type, a bisphenol AD type, a bisphenol S type, and a bisphenol F type can be used. Usually, this vinyl ester resin is blended with a styrene monomer, an acrylic monomer or the like as a crosslinking agent, but the form is not particularly limited.
[0025]
As the acrylic resin, what is called an acrylic syrup composed of a mixture of two or more of methyl methacrylate monomer, polyfunctional acrylic monomer, prepolymer, or polymer is usually used as a thermosetting type. The form is not particularly limited.
[0026]
In the case of a mixed system of two or more types of polyester resin, vinyl ester resin, and acrylic resin, the desired product quality is achieved by the characteristics of each resin and the interaction with the filler or the additive compound. The optimum blending is required, but the blending amount is not particularly limited.
[0027]
The filler can be used as one kind of aluminum hydroxide, silica, or glass powder, or as a mixture of two or more kinds. The blending amount of the filler is preferably 100 to 300 parts by weight with respect to 100 parts by weight of the thermosetting resin. If the amount is less than this range, the impact strength of the product is excellent, but the heat resistance cannot be sufficiently exhibited. Further, if it exceeds this range, the heat resistance is excellent, but the impact strength may be reduced. However, this is not particularly limited.
[0028]
The smaller the particle size of the filler, the more the impact strength of the artificial marble product can be improved. However, the viscosity of the resin composition suddenly increases, and the production tends to be difficult. When the particle size is increased, the clay of the resin composition for molding an artificial marble is lowered and there is no problem in production. However, since the impact resistance of the artificial marble product tends to decrease, the average particle size is from 5 μm to It is desirable to use one having a range of about 50 μm. However, this is not particularly limited.
[0029]
Moreover, when the surface of the filler that has been subjected to silane coupling treatment in advance is used, the adhesion between the filler and the resin can be improved, and the impact strength of the artificial marble product can be improved. .
[0030]
Furthermore, a curing agent is blended in the artificial marble molding resin composition.
[0031]
As the curing agent, 1,1,3,3-tetramethylbutylperoxy-2-ethylhexanoate, t-hexylperoxy-2-ethylhexanoate, or the like can be used. For example, in the case of vinyl ester resin, the blending ratio of the curing agent is preferably 0.5 to 5 parts by weight with respect to 100 parts by weight of the total amount of the resin and the crosslinking agent.
[0032]
In addition, the artificial marble molding resin composition may be blended with an ultraviolet absorber, a thickener, a release agent, glass fiber, and a colorant.
[0033]
A resin composition for a pattern material or a resin composition for molding an artificial marble is prepared by blending these blends containing a pattern material or a pattern material for molding an artificial marble at a predetermined ratio, and mixing and stirring them with a stirrer or the like. .
[0034]
In producing artificial marble from a resin composition for molding artificial marble, the resin composition for molding artificial marble is prepared by vacuum defoaming treatment under a reduced pressure of about 20 to 50 Torr and then released from the reduced pressure state. Wait for curing.
[0035]
The resin composition for pattern material thus obtained is poured into a plate-shaped or sheet-shaped mold, and the artificial marble molding resin composition is poured into a predetermined-shaped mold. The mold is heated at a temperature of 50 to 110 ° C. for 30 to 120 minutes.
[0036]
Resin composition for pattern materials by proceeding a copolymerization reaction of the reactive unsaturated group in these resin composition for pattern material or artificial marble molding resin composition with the polymerizable monomer in the resin by heating. Or a resin composition for molding artificial marble.
[0037]
The artificial marble molded article with the pattern material for artificial marble of the present invention obtained as described above is the one with a variety of colors, transparency, or pattern in the pattern material for artificial marble itself. As a result, it is possible to obtain an artificial marble with a granite pattern that has higher design, naturalness, luxury, or design than that of conventional products, and that can reduce product strength. There is no artificial marble that can be obtained.
[0038]
Such a molded article of artificial marble can be easily commercialized into a wash counter, kitchen counter, bathtub, wash bowl, or flooring or furniture surface material.
[0039]
【Example】
Hereinafter, the present invention will be described in detail by way of examples.
(Example 1)
As a thermosetting resin, what mixed vinyl ester (Showa High Polymer Co., Ltd. Lipoxy R-804) and acrylic syrup (Mitsui Chemicals Co., Ltd. XE924-1) by the compounding ratio of 95/5 was used, In addition, aluminum hydroxide (H-320
(A) = resin / filler / colorant = 100/90 / brown toner 0.4
(B) = resin / filler / colorant = 100/120 / beige toner 0.35
(C) = resin / filler / colorant = 100/150 / white toner 0.6
(D) = resin / filler / colorant = 100/180 / black toner 0.25
The four types of resin compositions for pattern materials were prepared. Further, 3.0 parts by weight of a curing agent (Nippon Yushi Co., Ltd. Percure HO) was added to each, and this was stirred and mixed for 30 minutes under a vacuum of 20 Torr, and then 0.8 mm thick. The mold is molded into a sheet-shaped mold, heated at a mold temperature of 95 ° C. for 30 minutes to be cured, crushed with a crusher and classified, and the pattern material a, pattern material b, pattern material c in FIG. A pattern material d was obtained. Next, (A) = resin composition (a) / pattern material b / pattern material c / pattern material d to the resin composition for pattern materials of the above (a), (b), (c) (unit: parts by weight) = 100 / 3.5 / 2.5 / 1.5
(B) = resin composition (b) / pattern material a / pattern material c / pattern material d = 100 / 3.0 / 2.0 / 1.0
(C) = resin composition (c) / pattern material a / pattern material b / pattern material d = 100 / 2.5 / 5.5 / 2.5
Three types of resin compositions for pattern materials were prepared. Further, 3.0 parts by weight of a curing agent (Percure HO manufactured by Nippon Oil & Fats Co., Ltd.) was added to each, and this was stirred and mixed for 60 minutes under a vacuum of 20 Torr. It is poured into a mold to be formed into a sheet having a thickness of 85 mm, cured at a mold temperature of 95 ° C. for 25 minutes, crushed by a crusher and classified, and again the pattern material a, pattern material b, pattern of FIG. The material c, the pattern material d = the pattern material a ′, the pattern material b ′, the pattern material c ′, and the pattern material d ′ were obtained.
Furthermore, to the resin composition for pattern materials of the above (a) (b) (c) (unit is part by weight),
(A) ′ = resin composition (a) / pattern material b ′ / pattern material c ′ / pattern material d ′ = 100 / 2.5 / 1.5 / 1.5
(B) ′ = resin composition (b) / pattern material a ′ / pattern material c ′ / pattern material d ′ = 100 / 2.5 / 1.0 / 2.0
(C) ′ = resin composition (c) / pattern material a ′ / pattern material b ′ / pattern material d ′ = 100/3. 0 / 4.0 / 3.0
Three types of resin compositions for pattern materials were prepared. Further, 3.0 parts by weight of a curing agent (Percure HO manufactured by Nippon Oil & Fats Co., Ltd.) was added to each, and this was stirred and mixed for 60 minutes under a vacuum of 20 Torr. It is poured into a mold to be molded into a sheet of 7 mm thickness and a mold to be molded into a plate of 5 mm thickness, heated at a mold temperature of 95 ° C. for 40 minutes, cured, crushed with a crusher, and classified. 1 is 1.0 to 4.0 mm, the pattern material A ′, the pattern material B ′, the pattern material C ′ of FIG. 1, and the flat pattern material A ″ having an average particle diameter of 1.0 to 5.0 mm, B "and pattern material C" were obtained.
[0040]
Next, the pattern material resin composition (a) is used as a resin composition for molding artificial marble, and the pattern material A ′, pattern material B ′, pattern material C ′, pattern material A ″, pattern material. B ", pattern material C" is used as a pattern material for artificial marble, and the resin composition for pattern material (a) used as a resin composition for molding artificial marble. B ′ = 3.5 parts by weight, Pattern material C ′ = 1.0 parts by weight, Pattern material A ″ = 2.0 parts by weight, Pattern material B ″ = 2.0 parts by weight, Pattern material C ″ = 2.5 A resin composition for artificial marble containing a pattern material for artificial marble was prepared by blending parts by weight. Further, 3.0 parts by weight of a curing agent (Nippon Yushi Co., Ltd. Percure HO) was added, and this was stirred and mixed for 60 minutes under a vacuum of 20 Torr, and then set to a thickness of 12 mm in a predetermined shape. Injected into the cast mold, and heated and cured at a mold temperature of 95 ° C. for 100 minutes, a granite-patterned pattern containing a pattern material for multicolored artificial marble shaped as shown in FIG. An artificial marble molding was obtained.
[0041]
【The invention's effect】
As described above, in the invention according to claim 1 of the present invention, it is added to the artificial marble pattern material composition for obtaining the artificial marble pattern material to be mixed with the artificial marble molding resin composition. As a pattern material to be used, since a pattern material obtained by repeating one or more times by adding and blending another pattern material to another pattern material composition, molding and curing, and pulverizing and classifying is used, higher designability, An artificial marble having a granite pattern with high naturalness, luxury, or high design can be produced . In the present invention, the artificial marble pattern to be blended with the resin composition for molding an artificial marble is used. As a pattern material added to and blended with a pattern material composition for artificial marble to obtain a material, another pattern material is added and blended with another pattern material composition, molded, cured, and pulverized and classified once or more. Since the pattern material obtained in this way is used, In obtaining one or more kinds of pattern materials mixed in a pattern material for a natural stone, it can be easily obtained by repeating the same process as that for obtaining a pattern material for artificial marble one or more times. Is.
[Brief description of the drawings]
FIG. 1 is a flowchart showing a manufacturing sequence of a method for manufacturing an artificial marble according to the present invention.
FIG. 2 is a perspective view showing an example of an artificial marble molded product obtained by the present invention.
FIG. 3 is an explanatory diagram showing details of the pattern material for the artificial marble.
[Explanation of symbols]
1 Artificial marble molding
Claims (1)
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2001392108A JP3700647B2 (en) | 2001-12-25 | 2001-12-25 | Manufacturing method of artificial marble |
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| JP2001392108A JP3700647B2 (en) | 2001-12-25 | 2001-12-25 | Manufacturing method of artificial marble |
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| Publication Number | Publication Date |
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| JP2003191254A JP2003191254A (en) | 2003-07-08 |
| JP3700647B2 true JP3700647B2 (en) | 2005-09-28 |
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| JP2001392108A Expired - Lifetime JP3700647B2 (en) | 2001-12-25 | 2001-12-25 | Manufacturing method of artificial marble |
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Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN101579886A (en) * | 2008-05-12 | 2009-11-18 | 有限公司麦泰格 | Manufacturing method of artificial marble |
| CN102416651A (en) * | 2011-10-21 | 2012-04-18 | 云浮市传奇岗石有限公司 | Twill multi-color artificial stone and production method thereof |
| CN107628766A (en) * | 2017-10-23 | 2018-01-26 | 淮南舜天合成材料有限责任公司 | A kind of preparation method of curing agent for resin anchoring agent |
Families Citing this family (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP5645258B2 (en) * | 2010-11-22 | 2014-12-24 | パナソニックＩｐマネジメント株式会社 | Manufacturing method of artificial marble |
-
2001
- 2001-12-25 JP JP2001392108A patent/JP3700647B2/en not_active Expired - Lifetime
Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN101579886A (en) * | 2008-05-12 | 2009-11-18 | 有限公司麦泰格 | Manufacturing method of artificial marble |
| CN102416651A (en) * | 2011-10-21 | 2012-04-18 | 云浮市传奇岗石有限公司 | Twill multi-color artificial stone and production method thereof |
| CN107628766A (en) * | 2017-10-23 | 2018-01-26 | 淮南舜天合成材料有限责任公司 | A kind of preparation method of curing agent for resin anchoring agent |
Also Published As
| Publication number | Publication date |
|---|---|
| JP2003191254A (en) | 2003-07-08 |
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