JPH0343561A - Decorative plate with stone tune pattern and manufacture thereof - Google Patents

Abstract

PURPOSE:To improve the quality and production efficiency by extrusion-molding a mixture of a natural gravel aggregate with a synthetic resin binding agent into a plate shape or laminating a mixture, in which fire resistant thermo-setting synthetic resin is used as the resin, with an inorganic base layer part to be thermally pressed thereafter polishing a surface. CONSTITUTION:A natural gravel aggregate 11 and a synthetic resin binding agent 12 of polyester or the like are formed by extrusion molding into a plate shape thereafter thermally pressed, and a decorative plate 1 is formed by polishing a surface. Next as a separate mode, an inorganic base layer part 2, in which a fire resistant thermo-setting resin binding agent is contained in a main aggregate of aluminum hydroxide, is provided. Then after a surface layer part 1, consisting of the aggregate 11 and fire resistant thermo-setting synthetic resin 12', layer part 2, reinforcing layer 21 and a backing layer 22 are integrally laminated by a thermal press, a decorative plate 1' is formed by polishing a surface. In this way, a crack can be prevented with no necessity for slice work, further production can be efficiently attained by a fixed quality.

Description

DETAILED DESCRIPTION OF THE INVENTION (Field of Industrial Application) The present invention relates to a decorative board with a stone-like pattern used mainly for indoor floors or walls of offices, stations, underground malls, and other public facilities, and a method for manufacturing the same.

(Conventional technology) Recently, decorative boards made of natural gravel hardened with resin or cement and polished to expose the cut surfaces of the gravel have been widely used as interior and exterior materials for buildings, paving materials, etc. It started to be done. In addition, the applicant has filed a patent application for patent application No. 61-1704.
No. 88 (Japanese Unexamined Patent Publication No. 63-027246) proposed an inorganic decorative board with a stone-like pattern in which sliced natural stone plates were laminated together with an adhesive or the like on a flame-retardant inorganic substrate layer.

These decorative laminates have the texture of natural stone, have an excellent decorative effect, and are highly valued for their practical value in the above-mentioned applications.

(Problems to be Solved by the Invention) By the way, the above-mentioned decorative board made of natural sand and gravel hardened with resin is made by mixing natural sand and gravel with a synthetic resin, filling it into a predetermined mold, hot pressing, and then coating the surface. Made by polishing. If the surface is not evenly leveled after filling the mold, the subsequent hot pressing will result in so-called uneven tightening (roughness), resulting in variations in quality.

This type of leveling work is generally done manually, so
This required time and effort, which was a major factor hindering manufacturing efficiency, and was also a cause of artificial variations in quality.

In addition, in the case of laminating the above-mentioned sliced stone plate and inorganic substrate layer, it is necessary to slice the natural stone into 1 to 5 mm thick pieces, but since it is easy to cause cracks, it is difficult to cut, transport, and handle the natural stone. It was necessary to pay close attention to this, and here too there were problems in terms of manufacturing efficiency.

The present invention has been made in view of the above, and it is an object of the present invention to provide a novel stone-like patterned decorative board that can be manufactured efficiently and with constant product quality, and an effective method for manufacturing the same.

(Means for Solving the Problems) The present invention will be explained based on the accompanying drawings. Fig. 1 is a perspective view showing one embodiment of the decorative board of the present invention, Fig. 2 is a longitudinal sectional view of the same embodiment, Fig. 3 is a view similar to Fig. 2 of the same embodiment, and Fig. 4 is a view of the present invention. FIG. 5 is a process diagram showing an example of the manufacturing method, and FIG. 5 is a process diagram of another embodiment.

That is, the stone-like patterned decorative board 1 according to the first aspect of the present invention,
The main components are natural sand and gravel aggregate 11... and synthetic resin binder 12, and a mixture of these is temporarily formed into a plate shape using an extrusion molding machine, then hot pressed, and the surface is polished. The main points are as follows.

In addition, the stone-like patterned decorative cutting according to the second embodiment has an inorganic base layer part 2 whose main aggregate is aluminum hydroxide and which contains a flame-retardant thermosetting resin binder.

The surface layer portion 1, which is a mixture of natural sand and gravel aggregate 11... and a flame-retardant thermosetting synthetic resin binder 12' as a main component, is laminated and integrated using a heat press, and the surface thereof is polished. The main points are as follows.

Furthermore, the method for manufacturing a stone-like patterned decorative board according to the present invention includes mixing the natural sand and gravel aggregate 11 and a synthetic resin binder 2 as main components, and extruding the mixture 10 using an extrusion molding machine 4. The gist is that after temporarily molding 100 into a plate shape, it is hot pressed 5 and the surface is polished.

The aggregate 11 is natural gravel (including crushed stone) produced in mountains, rivers, or beaches, and has a grain size of 0.5 to 15 m, preferably 1 to 9 m. If the grain size is less than 0.5 mm, the cut surface of each gravel will not be exposed even after polishing, and a stone-like texture will not be developed.
This is because if it exceeds 5+mn, it is difficult to mix uniformly with the binder, and it becomes necessary to make the gap between the screw and cylinder of the extruder 4 larger than that, making extrusion difficult.

As the binder 12 (12'), polyester resin is most desirable from the viewpoint of transparency, but resins such as phenol resin, melamine resin, acrylic resin, polydiphenyl oxide resin, and their derivatives can also be employed. In particular, as the flame-retardant thermosetting synthetic resin binder 12' according to the second embodiment, these thermosetting resins other than polyester resins and acrylic resins are used.

The mixture of the aggregate 11 and the binder 12 is transferred to an extruder 4.
When temporarily molding into a plate shape, it is desirable to add a thickener such as magnesium oxide, calcium oxide, beryllium oxide, calcium hydroxide, zinc oxide, or the like. This is to improve shape retention and extrudability during accelerated molding. In addition, lubricants and coupling agents, calcium carbonate, silica sand, and calcite powder are used to improve extrudability and various properties of the decorative plate 1.

It is also possible to appropriately add inorganic fillers such as calcium silicate powder, coloring pigments, and the like.

In a mixture containing the above aggregate and synthetic resin binder as main components,
The amount of aggregate is 60-90% by weight, the binder is 5-20% by weight, and if a thickener is used, it is 0.1-30% by weight (preferably 0.3-0.7% by weight). . If the amount of aggregate is less than 600% by weight, the amount of aggregate exposed on the surface will be small and a stone-like pattern will not be developed, while if it exceeds 90% by weight, the binding force by the binder will be weak. Furthermore, if the amount of the binder is less than 5% by weight, the bonding force will be weak, and if it exceeds 10% by weight, the resin will become rich and the stone-like feel will decrease. Furthermore, if the amount of the thickener is less than 0.1% by weight, the thickening effect will not be sufficient;
If it exceeds 0% by weight, extrusion molding becomes difficult.

The inorganic base layer part 2 in the decorative board according to the second embodiment uses aluminum hydroxide (AQ203.3H, ○) as the main aggregate, but also contains calcium carbonate, silica sand, calcite powder, calcium silicate, Zeolite, kaolin, bentonite, acid clay, etc. are also used. Furthermore, as a reinforcing material,
Mineral fibers (asbestos, etc.), inorganic fibers (glass fibers, ceramic fibers), gold fibers (iron fibers, aluminum fibers, whiskers, etc.), natural fibers (cotton, linen cotton, etc.), synthetic chemical fibers (
Fiber chops of vinylon, nylon, Tetron, etc.) are also used. As the flame-retardant thermosetting binder in this embodiment, the above-mentioned flame-retardant thermosetting resin is used.

The above aluminum hydroxide powder serves as a mechanical strength material for the base layer 2, and is blended in an amount of 40 to 97% by weight (preferably 50 to 85% by weight) based on the total amount, and is at a molding temperature of 2.
There is no thermal change below 00℃, but when the ambient temperature is 300~5℃
When the temperature reaches 00° C., crystal water is released to suppress combustion, and at the same time, it becomes AQzO3 as a heat-resistant material, giving the base layer portion 2 quasi-inflammability or non-flammability. If the blending amount is less than 40%, it will be insufficient to obtain quasi-nonflammability, and if it exceeds 97%, the binding strength will decrease, so the above range of 50 to 85% is desirable. However, in order to provide non-flammability, it is necessary to mix the content in the range of 70 to 97%.

The auxiliary aggregate is used to improve the mechanical strength of the base layer 2, reduce costs by increasing the amount, or as an auxiliary binder and to provide fluidity and increase the amount during molding.The amount used is as follows: The amount is 77% or less, and if it exceeds 77%, nonflammability is impaired, and the desirable range is 15 to 45%.

Reinforcements are used to further improve the mechanical strength of the base layer 2 and are added up to 15%, preferably from 2 to 10%.

The binder is a flame-retardant thermosetting resin that gives mutual molding fluidity to the above materials and can be cured by heat pressure, and the amount used is 3.
~12%. If the amount is less than 3%, the binding strength will be insufficient, and if it exceeds 12%, even if the amount of aluminum hydroxide is large, it will not be a noncombustible material. It is preferably 6 to 10%.

A reinforcing layer 21 or a backing layer 22 is also used on the back surface of the base layer 2 to reinforce it and prevent it from warping or bending. As the reinforcement M21, a glass fiber cloth net or the like is used. Further, as the backing layer 22, a fibrous base material impregnated with a thermosetting resin or a thermoplastic resin and dried is used.

The reinforcing layer 21 and the backing layer 22 are used alone or in combination, and are integrated with the back surface of the base layer portion 2 during the hot pressing.

(Function) For convenience, the inventions according to the first aspect and the third aspect will be explained together. The stone-like patterned decorative board 1 in this embodiment is made by molding a mixture 10 mainly composed of natural sand and gravel aggregate 1 and a synthetic resin binder 12 into a plate shape using an extruder 4 into a plate bottom mold 100. After that, it is obtained by hot pressing 5, so that it is extruded into a plate-shaped body 100 of a certain shape before the hot pressing 5, and therefore, no leveling work as in the conventional method is required here. In addition, as a result of no longer requiring manual shearing work, there is no variation in shape due to uneven work, and after heat pressing 5, the aggregate 1
1 . . . and the joint openings 2 are compacted tightly, and a molded plate 100a of uniform and constant quality is obtained. Then, when the surface of the molded plate 100a is polished, the aggregate 11 existing on the surface is cut, and this can be seen in the polished surface of the hardened layer by the binder 12, giving it a texture similar to that of stone. .

In addition, in the decorative board according to the second embodiment, an inorganic base layer part 2 made of aluminum hydroxide as the main aggregate and bonded by a flame-retardant thermosetting synthetic resin binder, and an aggregate 1 of natural gravel.
1... and the surface layer 1 obtained by polishing the surface of the heat press molded body 100a of the flame-retardant thermosetting synthetic resin binder 12'. In addition, the entire material is quasi-nonflammable or noncombustible, making it suitable for use as an interior material for buildings.

Also.

The base layer part 2 and the surface layer part 1 are extremely strongly integrated by mutual fusion and curing of the thermosetting synthetic resin binder contained in both during heat pressing, and there is no fear of peeling between the layers. .

(Example) Next, an example will be described.

(Example-1) See Figure 4. (i) Preparation of raw materials for stone-like patterned decorative laminate; Each raw material was prepared as shown in Table 1 below.

The above-mentioned mixture was mixed using a mixer 3 and extruded using an extruder 4 to obtain a plate-shaped bottom product 100.

In this board bottom product 100, the aggregate 11...bonded foundation 2
Since it was not completely filled, it was porous, and the surface remained uneven due to the voids.

(City) Heat press molding; The above plate bottom product 100 was introduced into the heat press 5, and heated at 150°C.
Heat pressed at 200 kg/ad for 10 minutes.

Here, a heat press molded product 10 is made of aggregate, which is completely filled with a binder 12 between the aggregates, hardens, and has a dense and flat surface.
0a was obtained.

(iv) Surface polishing; The surface of the hot press molded product 100a was polished by about 2 mm using a polisher. The obtained polished product 1 has aggregate 1 in the surface area.
1... were cut, and these were found here and there in the hardened layer of the binder 12, giving a texture similar to that of stone.6 (Example-2)...See Figure 5. Preparation: The base layer material was prepared as shown in Table 2 below.

(if) Preparation of surface layer material; Surface layer materials were prepared according to the formulations shown in Table 3 below.

(iii) Layer stack of base layer material and surface layer material; 120g/rr for melamine resin liquid? of kraft paper was soaked and then dried, and the melamine resin was (50% (180g/
rrf) The impregnated and supported support material 22 is transferred to the belt conveyor 7
A glass net 21 was placed on top of the glass net 21. The above-mentioned base layer material 20 is kneaded by a co-kneader 6, and while being continuously supplied onto the backing material 22 and the glass net 21 on the belt conveyor 7 so as to have a constant layer thickness, the surface thereof is coated with a roll brush 71. was evened out. Further, the surface layer material 10 mixed in step 8!3 is continuously fed onto the base layer material 20 which is continuously fed while being leveled so as to have a constant layer thickness, and the surface is coated with a roll 72. It was smoothed by applying light pressure.

(iv) Hot press molding; Introducing the above layered product 100' into the hot press 5 at fixed length intervals,
Heat pressing was performed under the same conditions as above. Here, the base layer part 2 and the surface layer part 1 are completely hardened together with the backing material 22 and the glass net 21, and in the surface layer part 1, the binder 12' is completely filled between the aggregates 11... A hot press molded product ↓OOa' in which the surface was flattened was obtained.

(v) Surface polishing; The surface of the hot press molded product 100a' is polished by a polishing machine.
Polished to some extent. In the resulting polished product t', the aggregates 11 on the surface were cut and were found here and there in the hardened layer of the binder 12', giving it a texture similar to that of stone. Also,
The polished product t' satisfactorily passed the test as a nonflammable material.

It goes without saying that the present invention is not limited to the above-mentioned embodiments, and that other changes can be made without departing from the scope of the present invention.

(Effect of the invention) As mentioned above, in the stone-like patterned decorative board of the present invention and the manufacturing method thereof according to the first and third aspects, a mixture of natural sand and gravel aggregate and a synthetic resin binder is used. Since it is extruded into a plate shape and then heat pressed, there is no need for leveling work before pressing, and a uniformly compacted decorative board of a certain quality can be obtained, making it possible to increase production.

In addition, in the case of the decorative board according to the second aspect, the raw materials for the base layer and the surface layer are mixed, layered, and integrated by heat pressing, so it is not necessary to cut the stone into slices as in the conventional case. There is no reduction in yield due to the occurrence of cracks. Moreover, since both layers are flame retardant, it can be used as a quasi-non-flammable or non-flammable construction board.

In both of the above decorative boards, the cut surface of the aggregate is exposed on the polished surface, and together with the hardened layer of binder resin, it has the texture of natural stone, making it an excellent alternative to natural stone. Its practical value as an indoor flooring material or wall material is extremely great.

[Brief explanation of drawings]

Fig. 1 is a perspective view showing an embodiment of the decorative board of the present invention, Fig. 2 is a longitudinal cross-sectional view of the same embodiment, Fig. 3 is a view similar to Fig. 2 of the sentencing mode, and Fig. 4 is a manufacturing method of the present invention. A process diagram showing an example of the method, FIG. 5 is a process diagram for Sentencing S. (Explanation of symbols) 1.1'... Decorative board with stone-like pattern (surface layer), 1 piece.
... aggregate, 12.12' ... synthetic resin binder,
2... Base layer part, 4... Extruder, 5... Heat press. -And more-

Claims (1)

[Claims] 1. The main ingredients are natural sand and gravel aggregate and a synthetic resin binder,
After temporarily molding these mixtures into a plate shape using an extrusion molding machine,
A decorative board with a stone-like pattern made by heat pressing and polishing the surface. 2. An inorganic base layer containing aluminum hydroxide as the main aggregate and a flame-retardant thermosetting resin binder is mixed with natural sand and gravel aggregate and a flame-retardant thermosetting synthetic resin binder as the main ingredients. This is a decorative board with a stone-like pattern, which is made by heat-pressing the surface layer and polishing the surface. 3. It is characterized by mixing natural sand and gravel aggregate and a synthetic resin binder as main ingredients, temporarily molding the mixture into a plate shape using an extrusion molding machine, then hot pressing and polishing the surface. A method for manufacturing a decorative board with a stone-like pattern. 4. The manufacturing method according to claim 3, wherein the mixture of aggregate and binder further contains a thickener.