JPH03170355A - Production of artificial marble - Google Patents

Abstract

PURPOSE:To produce artificial marble having a solid feeling due to a difference in color tone by molding a plastic containing inorganic granules mixed therein, applying an external force to the surface layer part of the resultant molded product before complete curing thereof and partially deforming the aforementioned surface layer part. CONSTITUTION:A plastic such as an acrylic resin containing inorganic granules mixed therein is cast into a forming mold, cooled and molded into a required shape. Calcium carbonate, aluminum hydroxide, etc., are used as the aforementioned inorganic granules. Granules having a large grain diameter and granules having a small grain diameter are preferably used together and the granules are mixed in an amount of preferably about >=70wt.% based on the plastic. In a state of curing advanced to an extent so that the resultant molded product may not be deformed without applying an external force thereto before the complete curing of the plastic in the molded product, the external force is applied to the surface layer part of the molded product to partially deform the molded product. In the process, part of the molded product around projecting parts provided in the above-mentioned forming mold can be deformed with the projecting parts in releasing thereof from the mold. The density of the inorganic granules in the aforementioned part is changed to a low or high value with the deformation to cause a difference in color tone and afford artificial marble having a solid feeling.

Description

[Detailed description of the invention] {Industrial application field} The present invention relates to a method for manufacturing an artificial surrogate stone.

{Prior Art} As a method of V-laying artificial surrogate stones used for buildings and other purposes, for example, the method disclosed in Japanese Patent Publication No. 55-43422 is known.

The method for producing an artificial surrogate stone disclosed in this publication involves adding an average particle size of 3 to 15 IIm to an acrylic resin, and an average particle size of 3 to 15 IIm.
Aluminum hydroxide particles of 0 to 100 um are mixed and formed into a plate shape or the like.

{Problem to be solved by the invention} The conventional manufacturing method described above involves mixing acrylic resin and aluminum hydroxide particles and molding it into a plate shape. The transparency and aluminum hydroxide particles give it the feel of natural marble.

However, since it is simply a mixture of acrylic resin and aluminum hydroxide particles and molded, the resulting Jinji Marble is almost the same overall, with no difference in color and no variation. It lacks a sense of three-dimensionality due to its lack of natural marble.

The present invention solves the above problems, and
We propose a manufacturing method that can produce artificial marble with a three-dimensional effect by creating a difference in color tone.

{Means for solving the problem} The third invention in the method for producing artificial marble of the present invention is to shape plastic mixed with inorganic powder into a desired shape, and to completely harden the plastic. Previously,
It is characterized in that when hardening has progressed to the extent that it will not deform unless external force is applied, an external force is applied to the surface layer of the precept-shaped article to partially deform it.

The means for partially changing the surface of the molded article includes:
For example, the surface of a certain shaped product is scratched with a slightly sharp edged tool to deform that part, or a certain shaped crystal is pressurized with a rod or a mold material to partially deform it. In addition, deformed parts that occur on the surface 3 of a shaped product can be removed by finishing processing such as polishing.
It is also possible to leave a part of the four parts created by pressing with the mold material and make a pattern out of it.

The second invention involves injecting plastic mixed with inorganic powder into a mold having a protrusion on the surface corresponding to the surface of the molded product, and before the plastic is completely hardened.
The molded article is characterized in that when the curing progresses to such an extent that it will not deform without applying an external force, the shaped article is released from the mold, and the protruding portion deforms the surrounding molded article.

The plastic in the first to second inventions or, for example,
It is possible to use any material such as polyester or acrylic resin. As the inorganic powder mixed into the plastics, it is customary to use calcium carbonate, aluminum hydroxide, and other suitable materials. In addition, these inorganic powders and granules, as in the conventional example,
Use small and large particle sizes for TIF, and increase the amount of inorganic powder in plastics to about 70% by weight or more, or add inorganic powder to plastics by the time the plastics gel. It is suitable for maintaining the inorganic powder and granules dispersed in a substantially uniform state throughout the plastics by reducing sedimentation of the particles.

Then, by applying an external force to the molded product where the hardening of the plastic has progressed, the surface layer is partially deformed, so that the hardening of the plastic mixed with inorganic powder and granules progresses gradually. That's appropriate. For example, 10-20
After about 24 hours at ℃, the curing progresses to a degree suitable for deforming the surface layer of the precept-shaped article, as described above.
This is appropriate because the possible time for the deformation process of the shaped product becomes longer and the deformation state can be set almost arbitrarily. However, the time required for curing of the shaped article can be shorter or longer than the 24 hours.

{Function} The manufacturing method of the invention F described above is such that when the plastic mixed with inorganic powder or granules has hardened to the extent that it will not be deformed without the application of an external force before it is completely hardened, the molded product is It partially deforms the surface layer by applying an external force, and depending on the deformation means, degree of deformation, etc., the density, phase, or density of the inorganic powder or granular material in that part changes.

As a result, there is a partial difference in color tone due to the inorganic powder,
Moreover, it forms a pattern and gives a three-dimensional effect to the molded product.

In the second invention, since the protrusion provided on the mold enters a part of the molded product, the molded product is cured to a state suitable for partially deforming the molded product, and the molded product is cured. When separated from the protrusion, the protrusion deforms the surrounding molded part by pulling or pushing it. As a result, as in the first invention, the density of the inorganic granular wood changes, resulting in a difference in color tone.

{Embodiment} An embodiment of the first invention in Section C1 of the present invention will be described with reference to FIGS. 1 and 2.

In this example, in order to examine the curing state of Plasdix, three types of pellets A) and (B) were prepared in which only the amount of cobalt 6 octenoate as a curing accelerator was changed as shown in 1. , (C).

Each silk composition and its blending amount are as follows.

Composition Amount Calcium carbonate (particle size o.i ~ o, 4 IIlm)
113.6 kf calcium carbonate (particle size 0.0001
~O, 02+++m) 46.4 kg Room temperature curable unsaturated polyester 35.0 kg Styrene
To 5.0 kg of methyl ethyl to 0.32 kg of peroxide were added 1. of cobal octoate, 0.32 kg for (A), 0.36 kg for (B), and 0.40 kg for C).

Then, as shown in Figure ■, the long side wall 1 to be erected
As mentioned above, only the cobalt octate base was changed into three molds 2, which were formed with a relatively small spacing between a and 1b and a considerably deep depth compared to this spacing (A), (
Each of the compositions B) and (C) was thoroughly stirred and injected. In addition, all 7 types of certain type 2 are the same, so one of them is illustrated and the other 2M1
illustration is omitted.

The temperature of the composition injected into mold 2 was maintained at 20°C.

Said (A). The time elapsed until gelation of the plastics of each of the compositions (B) and (C) started was (A) 8 hours and 47 minutes (B) 7 hours and 30 minutes (C) 7 hours. By the time this gelation begins, the defoaming of each plastic has been completed, and the hardening due to the reaction of the plastics has progressed, and if no external force is applied, the plastic will deform if no external force is applied. The molded product 3 was removed from each mold 2 at 1-.
). In order to compare the degree of hardening of each molded product 3 in (C),
The tests were carried out at the same time after 24 hours had elapsed since the composition was mixed.

Each molded article 3 that was released from the mold had been cured to the point that it maintained its shape, but since the curing was still in progress, it was possible to deform it by applying an external force.

This deformation was easiest for molded product 3 in (A), followed by molded crystal 3 in (B), and curing of molded product (C) progressed the most.

Next, as shown in FIG.
A part of the surface layer was deformed. This scratch 1 was made immediately after release from the mold, after 2 hours, after 4 hours, and after 6 hours, and the width of scratch 4 generated at each time was as follows.

Immediately after release 2 hours later 4 hours later 6 hours later A 2.2
mm 1.5mm 1.0++on 0.
5+nmB 1.4+++m 1.01+111
1 0.601111 0.2+++mC
1.3im 0.6+++m 0.4+nI+
+0.2n+m The scratches 4 also deformed the surface layer of the molded product 3 at both openings 2, and the calcium carbonate particles in those areas also moved at the same time.

In order to completely cure the molded products 3, after 7 days have elapsed since each of the scratches described above, the surface of each molded product 3 is polished by 0.5 to 0.81 Ilm to remove the scratches 4 and finish the molded products 3. went.

In this way, when each molded crystal 3 is finished, there is a difference in color tone between the scratched part and the pond part due to the calcium carbonate particles, which creates a pattern.
I was also able to walk around the Hitoshi marble, which had a three-dimensional feel to it.

As mentioned above, by changing the width of the scratch 4 depending on the degree of hardening of the shaped product 3, it is possible to change the deformation state of the crystal 3 in that part, so the difference in color tone can be made almost arbitrary. It is possible to produce a wide variety of human marble.

The detailed illustration of the 'J7IA structure of the mold 2 was omitted, as it is partly or entirely horizontally disassembled in order to release the molded crystal 3, and is made of metal. It can be made of any material such as a board or wood.Is this mold 2 intended to be used with its long side walls 1a and Ib upright?
, 1b is small, and the plastic becomes adhesive to each inner open surface of the large area, which has the effect of preventing the calcium particles from settling before gelation. The mold 2 can have any configuration.

FIG. 3 shows another embodiment of the means for deforming the surface layer of the molded article.

In this embodiment, a petal-shaped recess 5 is formed by pressing a molded product 3 with a petal-shaped mold material (not shown), and the periphery of the recess 5 is adjusted depending on the degree of hardening of the molded product 3. The part is also deformed,
Changes occur in the density of the calcium carbonate grains in these areas, resulting in differences in color tone. It is also possible to leave a part of the recess 5 as a pattern.

FIG. 4 shows an example of the manufacturing method of the second invention. The compositions used in this example and their blending amounts are as follows: 11 Silk composition: Calcium carbonate (granules) Diameter 0.1 ~ 0.4 n+m) 62.2
kg calcium carbonate (particle size 0.00010.02mm
) 24.191or room temperature curable unsaturated polyester 17.8kFr styrene
3.8bz methyl ethyl gel peroxide 0.27bg cobal octenoate 7-
0.27 kg, the mold 2 has a relatively small interval between the upright long side walls Ia and Ib, and is formed with a considerably deep depth compared to this interval. A protrusion 6 is provided on the inner surface of the side wall 1a.

The above-mentioned silk compositions are mixed and stirred and poured into the mold 2, and the mold 2 is tilted downward by 1 m with the long side m and the wall 1a facing downward.

The temperature of the composition in mold 2 was maintained at 10.5°C.

The reason for the inclination of the mold 2 is to allow air bubbles to rise and be discharged without being caught on the lower side of the protrusion 6. In the case of the mold 2 having such a structure that there is no risk of bubble formation, it is unnecessary to incline the mold 2.

Eight hours and 44 minutes after mixing the morning preparations, the composition began to gel. The molded product 3 was then removed from the mold 2 after 24 hours had passed after mixing the composition.

Then, when the protrusion 6 provided on the long-side measuring wall 1a was separated from the molded product 3, the surrounding area was slightly pulled or pushed, causing the molded product 3 to partially deform. . The surface of this molded product 3 was finished to obtain artificial marble.

Similar to the artificial marble obtained in the embodiment of the first invention, the human marble produced in this way has a difference in color tone in some parts, which forms a pattern, giving it a strong three-dimensional effect. It was King's marble.

Note that on the surface of the shaped product 3 taken out from the mold 2,
Furthermore, it is also possible to use a knife or other tool to number and deform the scratches. The projecting portion 6 of the certain-shaped mold 2 may be tapered on all four sides so that the tip thereof is slightly larger. By shaping the protrusion 6 in this manner, the shaped product 133 can be more easily deformed by mold release.

{Effect of Yumei} As described above, the method for manufacturing an artificial surrogate stone of the present invention involves molding plastics mixed with inorganic powder such as calcium carbonate into a desired shape, and molding the plastics completely into a desired shape. Before hardening, when the hardening has progressed to the extent that it will not deform without applying an external force, the surface layer of the molded product may be
The molded product is partially deformed by applying an external force through a rod or other object or by using a protrusion provided on the inner surface of the mold.

In this way, when an external force is applied to the surface layer of a molded product and that part is deformed, the calcium carbonate and other inorganic powder particles dispersed in the molded product move at the same time, causing the density of the part to change. It varies roughly or densely. Therefore, there is a partial difference in color tone due to the distributed inorganic powder and granules,
This local difference in color tone creates a pattern and creates a three-dimensional effect, so it can be manufactured to be as beautiful as natural marble.

[Brief explanation of the drawing]

Figure 3 shows an embodiment of the present invention; the first is a perspective view of a mold, the second is a perspective view of a molded product, and the third is a perspective view of a molded product partially deformed by another deformation means. FIG. 4 is a perspective view of another embodiment. 2: Molding die, 3: Molded product, 4: @, 5: Recess, 6: Protrusion.

Claims (2)

[Claims] (1) Plastics mixed with inorganic powder or granules are molded into a desired shape, and before the plastics is completely hardened, when the hardening progresses to the extent that it will not deform without applying external force, the molding A method for manufacturing artificial surrogate stones that applies external force to the surface layer of the item to partially deform it. (2) Inject plastic mixed with inorganic powder into a mold with a protrusion on the surface corresponding to the surface of the molded product, and do not apply external force before the plastic has completely hardened. A method for producing an artificial surrogate stone, in which the molded product is released when hardening has progressed to such an extent that it does not deform, and the surrounding molded product is deformed by the protrusion.