JPH01317723A - Production of artificial marble - Google Patents

Abstract

PURPOSE:To produce artificial marble closely similar to marble imported from Italy and having a natural feeling by a method wherein a colored synthetic resin material for developing a patterns is suspended in a thermosetting synthetic resin material becoming a base material to prepare a material mixture which is, in turn, allowed to flow in a hopper while reciprocally moved in the longitudinal direction of the emitting orifice thereof. CONSTITUTION:A thermosetting synthetic resin material B for a base material having a curing agent mixed therewith is preliminarily poured in a raw material container 8 and a colored synthetic resin material C for developing a pattern is allowed to flow down to the surface of said material B and suspended on said surface to form a material mixture D. This material mixture D is allowed to flow in a hopper from the raw material container 8 so as to flow forwardly from the rear part of the hopper and a part of the colored synthetic resin material C stretched on the upper surface of the flow-down material mixture D in a line form is adhered to the inside surface 11 of the front wall of the hopper 6. The hopper 6 is reciprocally moved before and behind while the material mixture D is allowed to flow in and the material mixture D reciprocally meanders over the entire front and rear width of the hopper 6. The hopper 6 filled with the material mixture D by this method is positioned above the right end of a surface mold 2 to open an emitting orifice 12 and the material mixture D is poured on the entire surface of the surface mold 2.

Description

[Detailed description of the invention] (b) Industrial application fields The present invention relates to a method for manufacturing artificial marble.

(b) Conventional technology In the past, thermosetting synthetic resin materials such as unsaturated polyester mixtures were poured into molds with an opening on the top, and after curing, synthetic resin products such as washstand counters and tables were cast. There are methods for manufacturing tops, etc., and in addition,
As seen in Publication No. 1568, at the time of casting, a different colored synthetic resin material is mixed into the thermosetting synthetic resin material that serves as the base material to create a pattern, so that the surface of the product has a natural color. There was a method of manufacturing artificial marble that imitated the marble pattern of.

(C) Problems to be Solved by the Invention However, the appearance of a pattern in this method is strongly influenced by chance, and this chance can cause the distribution of stripes with moderate irregularity and the thickness of the stripes to vary. The bleeding of the pattern,
It is expected that contrast will occur and the texture of natural marble will be created, but when actually manufactured using this method, the stripes may be distributed significantly unevenly, or the stripes may be too thick or too thin. In addition, there are overwhelmingly many cases where the pattern is blurred or the contrast is too strong, giving it an unnatural feel, perhaps due to the texture of natural marble. It had the disadvantage of being low.

As mentioned above, it is strongly influenced by chance, so
In some cases, products with a natural texture were produced with a good balance of stripe distribution, stripe thickness, pattern bleeding, contrast, etc., but there was no established method to control the irregularities mentioned above. However, yield improvement has not yet been achieved.

(d) Means for solving the problem In this invention, a thermosetting synthetic resin material as a base material and a colored synthetic resin material for pattern appearance are stored in a hopper,
While moving the hopper along the top opening surface,
A plate-shaped artificial marble is produced by discharging each synthetic resin material in a film form from the slit-shaped discharge port at the lower end of the hopper, supplying a band-shaped patterned synthetic resin material into the table mold, and heat-curing it. In a method of It is an object of the present invention to provide a method for manufacturing artificial marble, characterized in that a mixed material in which a resin material is suspended is caused to flow into a hopper by reciprocating in the longitudinal direction of a discharge port by a necessary means.

(e) Effect The above-mentioned marble pattern appearance phenomenon is strongly related to the flow and diffusion of the viscous synthetic resin material, and although such rheological phenomena are extremely difficult to analyze, until now The trial revealed the following, albeit qualitatively.

■The discharge port of the hopper for casting is formed into a roughly slit shape, and when the hopper is moved and the above synthetic resin material flows down into the mold in a roughly film-like manner, it comes into contact with the mold and coats the product surface. The majority of the synthetic resin formed comes from near the inner surface of the front wall at the front in the direction of movement of the hopper.

■The synthetic resin material for the base material, which makes up the majority of the material, and the small amount of the colored synthetic resin material, when flowing from a hopper to the level of casting, the composition of the colored synthetic resin material can be changed by just a small amount of mixing. It gradually spreads from the area where it is abundant to the surrounding areas.

■When the synthetic resin material flows into the hopper, if the colored synthetic resin material is suspended on the surface of the base synthetic resin material in the raw material container, when the raw material container is tilted and flows into the hopper, It is stretched out in the form of a line and lies on the upper surface of the synthetic resin material for the base material that is flowing down and flows down at the same time.

■The width of the colored synthetic resin material stretched in the line shape shown above is thick at first and gradually becomes thinner, but it does not necessarily become thinner uniformly, but it gradually pulsates irregularly as it becomes thicker and thinner. It's becoming.

■When the mixed material flows into the hopper, if the colored synthetic resin material comes into contact with the inner surface of the front wall of the hopper that is not covered with the mixed resin material or has a thin layer of the same material, the same colored synthetic resin material will It adheres to the inner surface of the front wall and hardly spreads as it is.

- The colored synthetic resin material adhering to the inner surface of the front wall sometimes does not flow out, but gradually flows out, dragged by the outflow of nearby synthetic resin materials.

The present invention was made based on the above knowledge, and first, a colored synthetic resin material for pattern appearance is gently injected onto the surface of the synthetic resin material for the base material before it flows into the hopper. Then, when the mixed material flows into the hopper, the colored synthetic resin material on the upper surface of the flowing mixed material is stretched in a line shape and flows down into the hopper.

During the above inflow, by reciprocating the necessary means, that is, the hopper or raw material container in the longitudinal direction of the discharge port, the colored synthetic resin material drawn in the above line shape is transferred to the width of the hopper. It can be stored in the hopper in a fully meandering state.

Next, by flowing the synthetic resin material in the form of a film through the slit-shaped discharge port of the hopper into the table mold, the colored synthetic resin material stored in the hopper in a meandering state is transformed into a synthetic resin material for the base material. It flows down into the surface mold as it flows down, and is injected into the lowest part of the surface mold, creating a striped pattern on the surface of the product whose length is in the direction of flow, that is, in the direction in which the hopper moves.

As mentioned above, the reason why the colored synthetic resin material meandering transversely to the flow direction forms a striped pattern in the direction perpendicular to this is due to the effect of turbulence in the flow of the mixed material in the hopper, considering the Reynolds number. Although it is difficult to imagine, since such a phenomenon has actually occurred in trials to date, it is reasonable to think as follows.

■When the mixed material flows in the hopper, there is a high probability that the linear colored synthetic resin material meandering in the horizontal direction will be separated due to the shearing effect at the interface where the flow velocity changes discontinuously.

■Since the colored synthetic resin material is located on the surface of the mixed material flowing into the hopper, the colored synthetic resin material
It will be located on the boundary between kit lobby-like spaces,
There is a high probability that the linear colored synthetic resin material will be rotated or split due to the flow of this mass.

■The colored synthetic resin rotated or divided as above,
From the middle part of the hopper with a wide horizontal cross-sectional area, it flows down in the form of a film from the slit-shaped outlet with a narrow cross-sectional area, and is stretched in the downstream direction, making the downstream direction, that is, the direction in which the hopper travels, the longitudinal direction. Becomes striped.

In addition, the pattern that appears when colored synthetic resin material adheres to the inner surface of the front wall of the hopper is that the colored synthetic resin material that was attached to the inner surface of the front wall of the hopper is replaced by the synthetic resin for the base material flowing down. Since it is caused by being dragged by the material, it naturally becomes a striped pattern whose length is in the direction of movement of the hopper.

In addition, the above-mentioned colored synthetic resin material, both when it is attached to the inner surface of the front wall of the hopper and when it is not, is greatly affected by the flow within the hopper, the flow down from the discharge port, and the flow within the table mold. does not diffuse, and gradually becomes thinner toward both sides, centering on areas with a large amount of colored synthetic resin material.Moreover, the synthetic resin material for the base material and the colored synthetic resin material for pattern appearance are placed in the hopper. As it flows back and forth in the longitudinal direction of the discharge port, the mixed position of the colored synthetic resin material is irregularly distributed over the entire width of the hopper in the direction of travel, and the amount of attached material also changes irregularly. The degree of irregularity depends on the probability, so the more the number of meanderings mentioned above, the smaller it becomes. Therefore, the distribution of stripes, the thickness of stripes, the contrast of the pattern, and the degree of bleeding can be controlled. By setting the optimal number of meandering back and forth cycles through several trials, it is possible to create a striped pattern on the surface of the product that closely resembles the pattern of Italian natural marble with a high probability.

Then, wait for the hardening of both synthetic resin materials injected into the surface mold, and then remove the mold to create the artificial marble product.

Effect) According to the present invention, the above method also has the following effects:
It is possible to control the distribution of stripes that appear on the surface of the product, the thickness of the stripes, the contrast and degree of bleeding, etc., making it possible to produce artificial marble with a natural texture that closely resembles Italian marble. .

(G) Example The method for manufacturing artificial marble according to the present invention will be explained in detail based on drawings of an apparatus for carrying out the method. The device (A) consists of a table mold (2) placed on a base (1) with an opening on the top surface with its longitudinal axis in the left and right direction, and a left and right opening mold (2) placed on the upper rear side of the table mold (2). Direction left and right rails (3) and the same rails (
3) a hopper support frame (5) that is suspended from the hopper so as to be movable from side to side and provided with front and rear rails (4) in the front and rear directions, and a hopper (6) that is supported by the front and rear rails (4) so as to be movable back and forth; A substantially cylindrical raw material container (8) with a bottom for flowing the synthetic resin material (7) into the hopper (6);
) for lifting lifts or chain blocks (
It consists of a heavy lifting machine such as a machine (not shown) and a back mold (not shown).

The table mold (2) has a substantially rectangular shape with its longitudinal direction in the left-right direction, and has a protruding portion (2a) protruding from its substantially central portion to form an opening into which a washbasin (not shown) is inserted.

The hopper support frame (5) has a vertical frame (10) that extends vertically downward from the left and right rails (3), and a vertical frame (10) that is attached to the lower end of the vertical frame (10) by approximately 2 times the longitudinal length of the hopper (6) described below. The front and rear rails (4), which are twice as long and have rollers (4a) on the upper surface, are arranged horizontally forward, and the front and rear rails (4) are connected to the handle (5b) of the lifting device (5a). ) can be raised and lowered by rotating the handle.

Therefore, the hopper (6) is suspended obliquely from the front and lower sides of the left and right rails (3) above the table mold (2), and is movable back and forth across the full front and rear width of the hopper (6). It is possible to move the table (2) left and right over the entire length of the table (2), and to adjust the height from the table (2).

As shown in FIG. 4, the hopper (6), which is one of the features of the present invention, is approximately rectangular in plan view with its longitudinal direction in the front and back direction.
The longitudinal direction includes the front-rear width and the length of the table (2), and is the left side surface when viewed from the front, that is, the inner surface of the front wall of the hopper (6) in the direction of movement of the first pass ( 11) is formed into a substantially planar shape and is inclined to be high in the front and low in the rear. Note that the side surface of the inner side surface (11) of the front wall is formed into a substantially rectangular shape.

In addition, a longitudinally slit-shaped discharge port (12) is provided at the bottom end of the hopper (6), and its length is equal to the longitudinal width of the table mold (2) and the length between the channels. A shutter (13) is provided below the outlet (12) to close the discharge port so that it can be opened and closed from below.

In particular, the opening/closing operation of the discharge port (12) is controlled by the shutter (
The thickness of the film-like synthetic resin material flowing down from the discharge port (12) can be adjusted by sliding the discharge port (13) in the left and right direction.

The back mold (not shown) is approximately plate-shaped and has an outer shape that matches the opening on the top surface of the front mold (2).

The artificial marble manufacturing apparatus used in the present invention is configured as described above, and in manufacturing the artificial marble, first, a thermosetting synthetic resin for base material mixed with a hardening agent is added to the raw material container (8). Material (B) is injected, and a colored synthetic resin material (C) for pattern appearance is gently poured onto the surface of the same material (B) and suspended on the surface to form a mixed material (0). .

The thus mixed material (b) is lifted together with the raw material container (8) using a lift or chain block, and the raw material container (8) is lifted up with a lift or chain block.
8) and flows into the hopper (6) with the discharge port (12) closed. At this time, as shown in FIG. 5, the fluid flows from the rear of the hopper (6) to the front.

By doing this, a part of the colored synthetic resin material (C) stretched in a line on the upper surface of the flowing mixed material (0) is transferred to the inner surface of the front wall located in front of the hopper (6) in the direction of movement. (11) and adheres to the inner surface (11) of the front wall.

By reciprocating the hopper (6) back and forth while flowing the mixed material (0) as described above, the material that has adhered to the inner surface (11) of the front wall of the colored synthetic resin material (C) is removed. , otherwise, it will meander back and forth across the full width of the hopper (6).

The hopper (6) filled with both mixed materials (0) in this way is positioned above the right end of the table mold (2) and the discharge port (
12) and let it flow down in a film form from the same discharge port.

When the mixed material (D) that has flowed down in a film reaches the upper right end of the table mold (2), the hopper (6) is moved to the left at a constant speed to make the minimum pass, and then the mixed material The mixed material (0) is poured over the entire surface of the table mold (2) by reciprocating left and right on the left and right rails (3) while flowing down in a film form from the discharge port (12).

During this casting, the degree of opening of the shutter (13) can be adjusted to optimally adjust the thickness of the mixed material (0) flowing down in the form of a film.

The surface of the mixed material (0) injected into the surface in this way (
2), on the surface of the product, a striped pattern parallel to the traveling direction of the hopper (6), that is, the length of the product appears, as explained in the section of the above-mentioned operation.

The contrast of this striped pattern and the degree of bleeding can be controlled by the number of times the raw material container moves back and forth when the mixed material (D) flows into the hopper (6), as also explained in the section above. .

Then, the back mold (9) is placed on the top surface of the cast mixed material (D) to make the top surface flat, and the mixed material (D) is
The upper surface of the material is coated to prevent air from inhibiting its hardening, and then heat curing is applied to harden the material, which is then demolded to produce the artificial marble product.

The embodiment of the present invention is constructed as described above, and first, prior to casting, the mixed material (RO) flowing into the hopper (6) is
By floating the colored synthetic resin material (C) for pattern appearance on the surface of the hopper (6) and flowing it into the hopper (6), the colored synthetic resin material (C) on the upper surface of the flowing mixed material (b) becomes linear. It flows into the hopper (6) while being stretched.

Also, at this time, the inflow is performed while the hopper (6) is reciprocated along the length of the discharge port (12).
Colored synthetic resin material drawn in the above line shape (C)
As shown in FIG.
6).

The width of the colored synthetic resin material (C) stretched in a line shape is thick at first and gradually becomes thinner, but it does not necessarily become thinner uniformly, but pulsates irregularly as it becomes thicker and thinner. It becomes thinner while doing so.

Therefore, the attached locations of the colored synthetic resin (C) are irregularly distributed over the entire surface of the inner surface of the front wall (January), and the amount of attached also varies irregularly, and furthermore, the degree of this irregularity is Since the number of meandering reciprocations increases, the distribution of adhesion points and the amount of adhesion can be controlled.

Next, the mixed material (D) is made to flow down in the form of a film from the slit-shaped discharge port (12) of the hopper (6) into the table mold (2), and the first pass of the hopper (6) is directed forward. By doing so, the inner surface of the front wall of the hopper (6) (1
The colored synthetic resin material (C) attached to 1) is dragged down by the nearby mixed material for base material (0), flows down to one place, and is injected into the lowest part of the table mold (2). Appears a pattern on the surface of the product.

In this way, the exposed synthetic resin material (C) that was attached to the inner surface (11) of the front wall of the hopper (6) is
Because it is dragged by the synthetic resin material (B) for the base material flowing down, it forms a striped pattern whose length is the direction of movement of the hopper (6), and the flow within the hopper (6).
It does not spread greatly due to the flow from the discharge port (12) and the flow within the table mold (2), and it gradually becomes thinner toward both sides, centering on the area where the composition of the colored synthetic resin material (C) is large. Moreover, as mentioned above, since the irregularities in the distribution of the attached parts and the amount of attached colored synthetic resin material (C) are controlled, the distribution of the stripes, the thickness of the stripes, and the contrast of the pattern can be controlled. By setting the optimal meandering number of times through several trials, you can create a striped pattern on the surface of the product that closely resembles the pattern of Italian natural marble. It is possible to produce artificial marble with a high probability of texture.

[Brief explanation of the drawing]

FIG. 1 is an overall front view of a manufacturing apparatus for carrying out the method for manufacturing artificial marble according to the present invention. FIG. 2 is a side view of the same. FIG. 3 is a sectional view taken along the line II in FIG. 2. FIG. 4 is a perspective view of the hopper. FIG. 5 is a perspective explanatory view showing the flow of the colored synthetic resin material into the hopper. FIG. 6 is an explanatory diagram showing the state of accommodation of colored synthetic resin materials in the hopper. (8): Synthetic resin material for base material (C): Colored synthetic resin material for pattern appearance (0): Mixed material (2) Two-sided type (6): Hopper (12): Discharge port

Claims (1)

[Claims] 1) A thermosetting synthetic resin material (B) serving as a base material and a colored synthetic resin material (C) for pattern appearance are stored in the hopper (6), and the hopper (6) ) along the top opening surface mold (2), each synthetic resin material (B) (
In the method of manufacturing a plate-shaped artificial marble by discharging C) and supplying a band-shaped patterned synthetic resin material into a surface mold (2) and heat-curing the material, heat-curing is carried out in a hopper (6). When accommodating the thermosetting synthetic resin material (B) and the colored synthetic resin material (C) for pattern appearance, the thermosetting synthetic resin material (B) as a base material is filled with colored synthetic resin material for pattern appearance. An artificial marble characterized in that a mixed material (D) in which a resin material (C) is suspended is caused to flow into a hopper (6) by reciprocating in the longitudinal direction of a discharge port (12) by a necessary means. Production method.