JPH0356536B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a new method for producing synthetic building materials that have a natural stone-like appearance.

Natural building materials, typically marble, give a warm feeling to those who come into contact with them due to their beautiful natural texture. For this reason, they are widely used in various places including walls, floors, etc.

These natural building materials are extremely superior, but because they are natural products, they are problematic in terms of resources, and they also have the disadvantage of being too heavy depending on where they are used.

For this reason, in place of these natural building materials, many synthetic building materials have been developed which have a texture similar to natural building materials, are light in weight, and have sufficient strength for practical use. One of these was the special public service in 1973.
There is method number 24447. This method involves kneading a thermosetting liquid resin and natural rock powder particles at a specific mixing ratio, molding and preforming, attaching natural rock powder particles or pigments to the surface of this preform, and then molding it into a mold. This is a method in which the material is placed on the surface, hot pressed, and the surface is polished. In this method, fine natural rock powder grains of 6 mm or less (2 thickness or less) are used. However, this method requires the operation of attaching natural rock powder particles or pigments to the surface of the preform, which increases the number of steps and the manufacturing time, making it difficult to manufacture industrially. cannot be said to be desirable. In addition, the obtained building material has a specific gravity of about 2.89 and a bending strength of 127.
It is about Kg/cm ² , and there is also the drawback that it is difficult to fully meet the demand for stronger strength due to recent technological advances.

The present inventor has focused on the above-mentioned difficulties, and in an attempt to overcome these difficulties, has conventionally conducted polishing of synthetic building materials. After discovering that the texture, bulk specific gravity, and strength are greatly affected, and as a result of further intensive research, we found that when crushed stone has a specific particle size composition, it is not necessary to separately attach crushed stone or pigment to the surface of the preform. However, the present inventors have discovered that it is possible to obtain a synthetic building material that has a texture similar to that of natural stone building materials and has extremely high strength, especially bending strength, even if the bulk specific gravity is small, and has thus completed the present invention. That is, the present invention uses particles whose particle size does not reach 3 mm.
80 parts by weight, 30 to 50 parts by weight for 3 to 6 mm, 10 to 20 parts by weight for those larger than 6 mm and not reaching 9 mm, and 9
A raw material mixture prepared by adding 5 to 20 parts by weight of crushed stone of 5 mm or larger, a thermosetting resin, its curing agent, and other additives as necessary is thoroughly kneaded and preformed as necessary. This relates to a method for producing synthetic building materials having a natural stone pattern, which is characterized in that the synthetic building materials are molded under pressure and heat, cooled, and then surface polished.

In the present invention, crushed stone is used in the specific particle size composition described above. As a result, crushed stone of each particle size of a predetermined size, for example, crushed stone from large particles to small particles, is well dispersed at a constant ratio, creating a texture and appearance similar to that of natural stone building materials, and each of these particles The well-formulated structure provides excellent mechanical strength even at a fairly low weight (ie, low bulk density).

As the thermosetting resin used as a type of raw material in the present invention, various types can be used as appropriate from a wide range, but typically unsaturated polyester resins, epoxy resins, phenol resins, etc. In more detail, examples of polyester resins include "Polylite PS261" and "Polylite PS261".
PB951” (all manufactured by Dainippon Ink and Chemicals Co., Ltd.)
can be given as a specific example. As a curing agent, any of the various curing agents can be effectively used as long as it is a curing agent for the above-mentioned thermosetting resin. For example, as a curing agent for unsaturated polyester, t-butyl benzoate ["Kayabutyl B"] is a typical example. (manufactured by Kayaku Nouri Co., Ltd.)].

Various types of crushed stone can be used, including crushed natural stone, as well as crushed pieces of ceramics and glass. Natural stones can be used not only in Japan, but also in a wide range of foreign countries.Specific examples include fragments of various types of granite such as red granite, rusted granite, Inada, Mansei, black granite, and Fujioka makage, and Shirataka. , Awayuki, Canary, Yamaguchi Chintz, Kurokansui, Arare, Ivory, Hakusan, Japanese Lotuso, Jajibori, Kuwao, Kozakura, and Aoisui are representative examples. Glasses of various compositions are selected from a wide range depending on the purpose, and are used as appropriate.
Various types of ceramics can also be used. The particle size composition of these crushed stones is extremely important, and if the particle size does not reach 3 mm, 15 to 30 parts by weight, preferably 20 parts by weight.
~25 parts by weight, 30 to 50 parts by weight, preferably 35 to 45 parts by weight, 10 to 20 parts by weight larger than 6 mm but not reaching 9 mm, preferably 12 to 18 parts by weight, and 5 parts by weight to 9 mm or more. ~20 parts by weight preferably 10-15
It is about parts by weight. At this time, if the crushed stone is outside this range, the intended effect of the present invention cannot be fully exhibited.

In the present invention, target building materials can be prepared from the above three types of raw materials, but various additives can also be used as necessary. Examples of such additives include fillers such as calcium carbonate, aluminum hydroxide, talc, clay, etc., and anti-shrinkage agents such as ``Floosene UF'' and ``Floosene UF80'' (manufactured by Seitetsu Kagaku Kogyo Co., Ltd.) used to prevent shrinkage. , internal mold release agents such as zinc stearate, various pigments, or inks. Preferred amounts of these various additives are as follows. However, the amount used below is for resin.
Per 100 parts by weight.

Filler: 20-150 (40-120) parts by weight Low shrinkage agent: 5-15 (7-10) parts by weight Internal mold release agent: 2-10 (3-8) parts by weight Pigment or ink: 20-
150 (40 to 120) parts by weight However, the above ( ) indicates a particularly preferred range.

When carrying out the method of the present invention, first, the above-mentioned various raw materials are sufficiently kneaded at a predetermined mixing ratio, and then the mixture is introduced into a molding machine. At this time, the kneaded material may be previously formed into a certain lump or sheet form and supplied to the forming machine.
The molding means may be a conventional pressurizing and heating molding method called a hot press, and the conditions at this time may be appropriately determined from a wide range, such as a pressure of 75°C.
Kg/ ^cm2 or more preferably around 75-150Kg/ ^cm2 , temperature 25
~160°C, preferably about 130~155°C. The molded product thus formed is cooled and finally its surface is polished.

Since the synthetic building material obtained by the method of the present invention contains crushed stone from large to small particles in the above specified ratio, it has the feel and appearance of natural stone building materials, and does not require separate preforming as in the conventional method. There is no need to attach crushed stone or pigments to the surface of the product. Furthermore, even if the bulk specific gravity is small, it has high mechanical strength, especially bending strength. For example, it has a bulk specific gravity of 2.30 and a bending strength of about 200 Kg/cm ² .

EXAMPLES The present invention will be specifically described below with reference to Examples.

Example The raw material mixture shown below was sufficiently kneaded with a mixer, introduced into a mold in a lumpy state, and hot pressed at 75Kg/cm ² and 155°C. After allowing this to cool, it was polished to obtain a synthetic building material. This building material had a pattern and texture very similar to natural marble or granite. The bulk specific gravity of this product was 2.3 and the bending strength was 180 Kg/cm ² .

Mixture Resin (Polylite PS-261) 6.89% (weight) (Polylite PB-956) 2.29% 〃 Hardening agent (Kayabutyl B) 0.14% Filling materials, etc. 6.89% 〃 Internal mold release agent, etc. 0.46% 〃 Low shrinkage agent 0.69% 〃 Crushed stone 9m/m～5m/m 13.77%〃 5m/m～3m/m 41.32% (weight) 3m/m～0m/m 27.55% (weight) 100% (weight)

Claims (1)

[Claims] 1 15 to 30 parts by weight of particles whose particle size does not reach 3 mm, 3
~30-50 parts by weight for 6mm, 9mm larger than 6mm
A raw material mixture prepared by adding crushed stones, a thermosetting resin, a curing agent thereof, and other additives as necessary, consisting of 10 to 20 parts by weight of stones that do not reach 9 mm and 5 to 20 parts by weight of stones that are larger than 9 mm. A method for producing a synthetic building material having a natural stone pattern, which comprises sufficiently kneading, preforming if necessary, molding under pressure and heating, cooling, and then surface polishing.