JP4052761B2 - Continuous production equipment for artificial marble with stripe pattern - Google Patents

Description

【００３６】
【発明の効果】
本発明の人工大理石の連続的製造装置によれば、人工大理石の厚み方向にも連続的に形成されたストライプ柄をもつ人工大理石が効率よく製造できる。また、ストライプ柄の柄模様についても、ストライプの間隔が一様でない極めて自然に近い外観を呈する製品が製造できる。また、カム形状あるいは駆動軸の回転数を変えるという僅かな条件変更で、所望の揺らぎのストライプ柄をもつ製品が製造可能である。
【図面の簡単な説明】
【図１】本発明の人工大理石の連続的製造装置を示す模式図である。
【図２】本発明の製造装置に用いる櫛状工具の例を示す図である。
【図３】本発明の製造装置に用いる櫛状工具の他の例を示す図である。
【図４】本発明の製造装置に用いるカムの形状を示す図である。
【符号の説明】
１ 成形セル
２ 液状樹脂供給手段
３ 櫛状工具
４ カム装置
５ ステンレス製ベルト
６ 枠
７ 樹脂放出口
８ 下層液状樹脂
９ 上層液状樹脂
１０ 液溜りの先端部
１１ 柄
１２ 歯
１３ 連結部材
１４ 整流板
１５ ゲージロール[0001]
BACKGROUND OF THE INVENTION
The present invention relates to an apparatus for continuously producing artificial marble having a stripe pattern.
[0002]
[Prior art]
Conventionally, a liquid resin is cured to produce artificial marble for use in a washstand counter or table top. As a method for manufacturing such a surface of artificial marble, a method of mixing a synthetic resin material having a different color when liquid resin is injected into a molding cell is disclosed in Japanese Patent Publication No. 59-1568 and Japanese Patent Publication No. 59-1568. It is known from Kaihei 1-317723.
[0003]
However, these conventional methods have a problem in that the reproducibility of the appearance of the pattern is lacking and the product yield for obtaining a good product is low. In addition, when used as artificial marble, the surface is often cut and it is necessary to retain the pattern on the surface, but the pattern disappears or changes significantly when cut. There were many things. Furthermore, when different materials are used for the appearance of patterns, there is a difference in the curing speed and the physical properties between the materials are likely to develop. Mechanical performance may be reduced.
[0004]
[Problems to be solved by the invention]
As a method for solving the above problems, the present inventors laminated different colored liquid resins in layers in a molding cell, moved a comb-shaped tool in the molding cell, and then cured the artificial marble. A manufacturing method was proposed in Japanese Patent Laid-Open No. 10-128771. By this method, a stripe pattern with a clear appearance can be simply formed, the pattern can be easily controlled, and a pattern can be continuously formed in the thickness direction.
[0005]
Also, Japanese Patent Application No. 10-86064 proposes an improved method of moving the inside of a forming cell while changing the interval between teeth of a comb-like tool, and the appearance of the stripe is not uniform and the appearance is almost natural. It is possible to produce artificial marble with a striped pattern.
[0006]
An object of the present invention is to provide a manufacturing apparatus for continuously manufacturing an artificial marble having such a stripe pattern on an industrial scale.
[0007]
[Means for Solving the Problems]
That is, the present invention comprises a moving molding cell, a liquid resin supply means for laminating at least two layers of different color liquid resins on the molding cell, and the teeth are brought into contact with the bottom surface of the molding cell. An apparatus for continuously producing artificial marble having a stripe pattern having a comb-shaped tool disposed therein , wherein a cam device for reciprocating the comb-shaped tool in a direction perpendicular to the moving direction of the cell is disposed , and the liquid A rectifying plate for imparting a certain flow direction to the flow pattern of the liquid resin on the bottom surface of the molding cell on the molding cell upstream of the resin supply means, and the rectifying plate reciprocating in a direction perpendicular to the moving direction of the cell. A continuous production apparatus for artificial marble, characterized in that a second cam device for movement is provided.
[0009]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, the present invention will be described with reference to the drawings.
[0010]
FIG. 1 is a schematic view showing a continuous production apparatus for artificial marble according to the present invention. As shown in this figure, the apparatus of the present invention basically includes a molding cell 1 that moves and a liquid resin supply means 2. And a comb-like tool 3 and a cam device 4.
[0011]
As the moving molding cell 1, for example, a moving cell made of a stainless steel belt 5 and a frame 6 for damming a liquid resin made of rubber or resin installed on both sides thereof can be used.
[0012]
The liquid resin supply means 2 is for supplying a liquid resin onto the molding cell 1, and in the present invention, it is necessary to laminate at least two layers of different colored liquid resins in layers, and therefore a plurality of resin discharge ports 7. The liquid resin discharged from each resin discharge port can be led from each liquid resin tank by a separate pipe, but the base liquid resin is led to the vicinity of the molding cell by one pipe and it is close to the resin discharge port. The color tone of the liquid resin can be easily changed by dividing into a plurality of pipes according to the number of different colored liquid resins and mixing different colorants for each of them. As this colorant mixing means, for example, an unstirred mixer can be provided.
[0013]
The liquid resin 8 to be injected into the lowermost layer of the molding cell exhibits a base color tone in a significant aspect of the product, and in this apparatus, the resin supply port of the liquid resin is arranged upstream of the molding cell to which the liquid cell 8 moves. . When the liquid resin is supplied onto the molding cell that moves from the resin discharge port, the liquid resin spreads on the molding cell and flows in the upstream direction of the molding cell against the movement of the molding cell. A parabolic reservoir tip 10 is formed in the upstream portion of the molding cell in balance with the supply amount. On the other hand, a liquid resin layer having a substantially uniform thickness is formed in the downstream direction. After laminating the lowermost layer liquid resin on the molding cell in this way, the liquid resin layered on the upper layer is separated from the other resin discharge port in the same manner as the lower layer without disturbing the lamination interface with the lower layer. And can be laminated continuously.
[0014]
The liquid resin after the lamination is preferably laminated in a uniform state in the molding cell in order to control the expression of the pattern, but even if the lamination thickness is partially uneven, it is directly striped. Does not affect pattern expression. The thickness of the laminated liquid resin is not particularly limited, but the thickness of each layer is preferably about 2 to 20 mm. In particular, when the thickness of the lower layer liquid resin is too thick, it is not preferable because it becomes difficult for the upper layer liquid resin to reach the bottom surface of the molding cell. In addition, if the thickness of the lower liquid resin layer is too thin, the pattern tends to be disturbed and difficult to control, and the product obtained is restricted in cutting thickness in order to maintain a stripe pattern. This is not preferable because it causes problems.
[0015]
The liquid resin used in the production apparatus of the present invention is usually a mixture, for example, a composition comprising a syrup, a filler, a color pigment, and a curing catalyst, which is a mixture of a monomer such as methacrylate and a polymer thereof. The Examples of the filler include inorganic fillers such as aluminum hydroxide, magnesium hydroxide, and calcium hydroxide, and organic fillers such as wood powder. Examples of the color pigment include white titanium oxide, zinc sulfide; yellow iron oxide yellow; black iron oxide black; red iron oxide red; blue ultramarine blue and phthalocyanine blue. Examples of the curing catalyst include tertiary butyl peroxymaleic acid, benzoyl peroxide, cumene hydroperoxide, tertiary butyl hydroperoxide, lauroyl peroxide, azobisisobutyronitrile and the like. In addition to these components, various components conventionally known as additive components for artificial marble, such as dyes, ultraviolet absorbers, flame retardants, mold release agents, fluidizers, thickeners, polymerization inhibitors, oxidation inhibitors An inhibitor or the like can be added.
[0016]
The viscosity of the liquid resin is preferably in the range of 300 to 5000 cp. If the viscosity is too high or too low, a stripe pattern is developed and it is difficult to control this. Moreover, sedimentation of additives, such as a filler and a coloring agent, can be prevented by selecting appropriately the viscosity of liquid resin.
[0017]
As the liquid resin, it is also possible to use a liquid resin in which the colorant proposed in JP-A-10-323848 is dispersed non-uniformly. When this liquid resin is used, a natural appearance with a remarkably improved quality can be obtained from the resulting artificial marble.
[0018]
In the manufacturing apparatus of the present invention, a comb-like tool 3 is disposed on a molding cell on the downstream side of the liquid resin supply means 2 with its tooth tips in contact with the bottom surface (stainless steel belt) of the molding cell. . When the liquid resin laminated on the molding cell passes through the comb-shaped tool arrangement portion, the liquid resin moves relatively in the liquid resin so as to spread the liquid resin on which the comb-shaped tool is laminated. Then, when the upper layer of the liquid resin of the upper layer penetrates to the bottom of the molding cell into the trace of the teeth of the comb-shaped tool, and the bottom surface is made a significant surface of the product, the stripe pattern on the trace of the teeth of the comb-shaped tool Will be formed.
[0019]
The moving speed of the molding cell is important in relation to the viscosity of the liquid resin. If the moving speed is too slow, the upper layer of different colored liquid resin cannot reach the bottom surface of the molding cell, and a stripe pattern cannot be formed. In general, the moving speed of the molding cell is preferably about 1 to 10 cm / second.
[0020]
As a comb-like tool used in the present invention, it is appropriate that the tooth part is made of a material that is inactive with respect to the liquid resin and does not exhibit adhesiveness, for example, a metal such as aluminum, Examples thereof include organic materials coated with polytetrafluoroethylene.
[0021]
FIG. 2 is a schematic view of a comb-like tool used in the present invention. As a tooth form of the comb-like tool, it is appropriate that the tooth length is sufficiently longer than the thickness of the laminated liquid resin so as not to cause unnecessary disturbance in the upper liquid resin. Moreover, as a width | variety of a tooth | gear (length of the orthogonal | vertical direction with the moving direction of a shaping | molding cell), 1-20 mm is preferable. The width of the teeth does not match the width of the stripe formed, but affects the width. The thickness of the teeth (the length of the molding cell in the moving direction) may be any thickness that maintains the mechanical strength of the teeth, and does not affect the formation of the striped pattern. As the cross-sectional shape of the teeth, streamline is not appropriate, and a square shape that generates turbulent flow in the liquid resin at the passage of the teeth is appropriate. Moreover, it is preferable that the shape of the front-end | tip of a tooth | gear has a flat surface so that it can closely_contact | adhere to the molding cell bottom face. The number of teeth of the comb-like tool may be one, and an appropriate number of teeth and tooth spacing can be selected according to the desired stripe pattern. As shown in FIG. 1, a plurality of comb tools can be used.
[0022]
Further, as the comb-shaped tool, a tool in which the handle 11 and the teeth 12 of the comb-shaped tool 3 as shown in FIG. 3 are connected directly via a flexible connecting member 13 without being directly joined can be used. When such a comb-like tool is used, the position of each tooth in the liquid resin slightly changes due to the resistance that the teeth receive from the liquid resin, so that the distance between the teeth slightly changes. In particular, when the comb-like tool is reciprocated by the cam device, these changes are amplified, and a handle with a natural fluctuation and a change in the interval and thickness of the stripes can be obtained.
[0023]
As the flexible connecting member, the movement of the tooth part does not follow the movement of the handle part of the comb-like tool and does not follow, and a moderately durable one can be used. Examples of the connecting means such as a chain and a film that do not have a restoring force, and elastic connecting means that has a restoring force such as a spring.
[0024]
In the manufacturing apparatus of the present invention, the cam device 4 is disposed, and this reciprocates the comb-shaped tool in a direction perpendicular to the moving direction of the forming cell. The tooth-to-tooth spacing within one comb tool or the relative tooth-to-tooth spacing between the comb tools varies with this reciprocation. This means that the comb-like tool is moved in a meandering manner relative to the forming cell while changing the interval between the teeth. As a result, fluctuations and spacing changes occur in the stripe pattern of the significant surface of the artificial marble as a tooth trace, and a more natural artificial marble can be obtained.
[0025]
The cam device used in the present invention is a general cam device composed of a drive node including a cam and a driven node. As the cam, a plate cam, a cylindrical cam, a disc cam, a spherical cam, a swash plate cam, an end cam, an accurate cam, and the like. Various types such as a moving cam can be used. FIG. 4 is a diagram illustrating various plate cam shapes used in the manufacturing apparatus of the present invention. By changing the shape of the cam arranged on the drive node, the comb-shaped tool connected to the driven node can be reciprocated in various ways, for example, reciprocating at a constant movement speed, or the movement speed can be changed slightly. Can be reciprocated. In addition, when a plurality of different cams are arranged for one drive shaft, and the reciprocating movements with different moving speeds and periods are caused by different comb tools, the tooth-to-tooth spacing between the comb tools is relative. To change. The reciprocating distance of the comb-like tool is usually about 5 to 50 mm, and the reciprocating period is usually preferably about 2 to 25 seconds.
[0026]
When a liquid resin in which a colorant is dispersed non-uniformly is used as the lowermost liquid resin, traces of the resin flow are likely to appear on the significant surface of the product due to the non-uniform dispersion of the colorant. In order to obtain a natural appearance, it is preferable that a flow direction in a certain direction is given to the flow pattern of the resin. For this purpose, a rectifying plate 14 is disposed on a molding cell upstream of the liquid resin supply means. you. If there is nothing between the resin supply port and the tip 10 of the liquid reservoir, the liquid resin supplied from the resin discharge port reaches the bottom (significant surface) of the molding cell only after flowing back to the tip of the liquid reservoir. . However, since the liquid resin is constantly in a state where there is almost no movement of the liquid resin at the front end of the liquid pool, the resin flow trace may be formed as an unnatural one. The rectifying plate is for positively imparting a certain direction to the flow pattern of the liquid resin on this significant surface, and the shape thereof is not particularly limited. For example, the rectifying plate is similar to a comb-like tool. Things can be used. However, it is preferable to use a tooth having a slightly wider width. Further, unlike the case of a comb-like tool, the tip of the tooth may be in contact with the bottom surface of the molding cell or may be slightly floated as long as it is immersed in the liquid resin.
[0027]
This rectifying plate is provided with another cam device so that the rectifying plate can be gently reciprocated in a direction perpendicular to the moving direction of the forming cell, as in the case of the comb-shaped tool. By moving the current plate, fluctuations can be imparted to the flow pattern of the liquid resin.
[0028]
The liquid resin after passing through the comb-shaped tool installation part is pressed with a gauge roll as necessary to adjust the laminated thickness, and then the liquid resin is cured according to a conventional method, and the cured product is taken out from the molding cell after curing. Artificial marble can be obtained.
[0029]
The obtained artificial marble has a stripe pattern formed on the contact surface with the bottom surface of the molding cell. The stripe pattern formed in this way is formed by flowing and mixing liquid resins of different colors while reciprocating the comb-like tool, so the stripe spacing is not uniform and the fluctuation of the appearance is almost natural. It is a stripe pattern with a line.
[0030]
The artificial marble produced by the production apparatus of the present invention can be used for kitchen top plates, bathroom vanities, bathtubs, tables, wall materials, furniture, interior accessories, etc. in a house.
[0031]
【Example】
Hereinafter, the present invention will be described more specifically according to examples. In the examples, “%” and “part” mean “% by weight” and “part by weight”, respectively.
Example 1
1000 parts of methyl methacrylate syrup (hereinafter abbreviated as “syrup”) composed of a mixture of 20% polymethyl methacrylate and 80% methyl methacrylate, aluminum hydroxide powder (BS-33, trade name, Nippon Light Metal Co., Ltd.) 1630 parts, 12 parts ethylene glycol dimethacrylate, 20 parts tertiary butyl peroxymaleic acid, 2 parts deionized water were mixed and stirred with a mixer to obtain a mixed slurry. After defoaming this mixed slurry in a vacuum vessel, 0.1 part of glycol dimercaptoacetate and 8 parts of slurry in which 25% of calcium hydroxide was dispersed in syrup were added and stirred to prepare a base mix. The viscosity of this base mix was 1000 cps.
[0032]
This base mix has a colorant composition no. 1 (the unit is a part relative to 100 parts of the base mix) is used as the lower layer liquid resin, and the colorant composition No. 2 was mixed as a liquid resin in the upper layer and discharged from a liquid resin supply means 2 onto a molding cell comprising a stainless steel belt 5 and rubber frames 6 installed on both sides thereof. The stainless steel belt 5 was moving at 46 mm / second, but the lower layer liquid resin flowed from the resin discharge port to the upstream part of the molding cell by about 0.8 m, and formed the tip part 10 of the liquid pool there. . The laminated thickness of the liquid resin after reaching the steady state was 7 mm for both the upper layer and the lower layer.
[0033]
A rectifying plate 14 is disposed at an intermediate portion between the tip of the liquid reservoir of the lower liquid resin and the resin discharge port of the lower liquid resin. The rectifying plate is a plate made of polytetrafluoroethylene having a length of 100 mm, a width of 30 mm, and a thickness of 3 mm arranged at an interval of about 150 mm, and the tip of the plate was separated from the stainless steel belt by 2 mm. Further, three comb-like tools were arranged at intervals of 80 mm in the moving direction of the molding cell, and the tips of the teeth were arranged in contact with the stainless steel belt 0.8 m downstream from the resin discharge port of the upper liquid resin. For the comb-shaped tool, 30 pieces of polytetrafluoroethylene teeth with a length of 120 mm, a width of 5 mm, and a thickness of 3 mm, each having a lead weight attached to the upper end, are spaced at irregular intervals of 10 to 40 mm. The thing of the shape as shown in FIG. 3 attached to the handle via a 60 mm long thread was used. The tips of the comb-shaped tool handles were disposed so as to come into contact with plate cams of different shapes, and were individually reciprocated gently. At this time, the rotational speed of the plate cam was 8.5 rpm, and the moving distance of the comb-shaped tool was 30 mm. In this way, the laminated mix after passing through the comb-shaped tool installation part was pressed with the gauge roll 15 to make the thickness uniform, and then heated and cured while moving to obtain an artificial marble. .
[0034]
The appearance of the obtained artificial marble had a stripe pattern like natural marble in which the interval between stripes and the thickness thereof were slightly changed. Further, even if the surface was polished by about 0.5 mm, the basic stripe pattern hardly changed.
[0035]
[Table 1]

[0036]
【The invention's effect】
According to the continuous production apparatus for artificial marble of the present invention, artificial marble having a stripe pattern continuously formed in the thickness direction of the artificial marble can be efficiently produced. In addition, with regard to the stripe pattern, a product having a very natural appearance in which the stripe interval is not uniform can be manufactured. Further, a product having a stripe pattern with a desired fluctuation can be manufactured by a slight change in conditions such as changing the cam shape or the rotational speed of the drive shaft.
[Brief description of the drawings]
FIG. 1 is a schematic view showing an apparatus for continuously producing artificial marble according to the present invention.
FIG. 2 is a view showing an example of a comb-like tool used in the manufacturing apparatus of the present invention.
FIG. 3 is a view showing another example of a comb-like tool used in the manufacturing apparatus of the present invention.
FIG. 4 is a view showing the shape of a cam used in the manufacturing apparatus of the present invention.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 Molding cell 2 Liquid resin supply means 3 Comb-like tool 4 Cam apparatus 5 Stainless steel belt 6 Frame 7 Resin discharge port 8 Lower layer liquid resin 9 Upper layer liquid resin 10 Liquid pool tip 11 Handle 12 Teeth 13 Connecting member 14 Current plate 15 Gauge roll

Claims (1)

A moving molding cell, liquid resin supply means for laminating at least two layers of different colored liquid resins on the molding cell, and a comb-like tool arranged with its teeth in contact with the bottom surface of the molding cell An apparatus for continuously producing artificial marble having a stripe pattern having a cam pattern for reciprocating the comb-shaped tool in a direction perpendicular to the cell moving direction , and upstream of the liquid resin supply means On the molding cell, a rectifying plate for imparting a constant flow direction to the flow pattern of the liquid resin on the bottom surface of the molding cell, and a second cam for reciprocating the rectifying plate in a direction perpendicular to the moving direction of the cell An apparatus for continuously producing artificial marble, characterized in that the apparatus is disposed .

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