JPH0383640A - Manufacturing method for imitation stone material finish surface and modifying type imitation stone material product - Google Patents

Abstract

PURPOSE: To form an artificial stone material-like finish surface excellent in the touch and imitation degree of a natural stone on a base material by successively pressing the part adjacently continuing to the irregular and non-uniform surface of a flexible uncured liquid resin mixture together with the continuous part corresponding to a separate surface by rolling pressure. CONSTITUTION: A mixture 1 prepared from a flexible uncured liquid synthetic resin binder, a color pigment, filler particles for a resin and a curing agent is applied to a base material 3 so that one surface thereof is bonded to the base material 3 and the other surface thereof shows an irregular and non- uniform liquid resin surface and the part adjacently continued to the irregular and non-uniform surface of the flexible uncured liquid resin mixture is successively continuously pressed together with the corresponding continuous part corresponding to a sheet 7 having an inner surface 7' smoothly finished constant by the pressure of a roller 9 and the resin mixture is compressed not only to allow the resin mixture to correspond to the inner surface 7' of the sheet 7 but also to exclude air from the gap between both of them. At a time of use, the sheet and the cured mixture are separated.

Description

[Detailed Description of the Invention] [Industrial Application Field] The present invention is directed to a surface imitating an artificial rock or stone (hereinafter referred to as stone-like), or a base material and base material imitating a natural stone block, panel, etc. relating to synthetic coatings.

[Conventional technology]

Typically, man-made or imitation natural stone products have been manufactured by casting or molding. However, casting or molding techniques have drawbacks such that the bottom shape or cast product is generally not the final product, and the manufacturing process is relatively expensive.

For example, US Pat. No. 3,341,396 discloses a method of coating a substrate with a simulated natural stone coating, but this has limitations, particularly regarding the geometrical meaning and orientation of surface application.

The inventor's earlier U.S. Pat. No. 4,385,088 discloses artificial decorative stone, but the technology is
This is not suitable for the purpose of the present invention.

SUMMARY OF THE INVENTION The present invention provides a low cost, thin layer engineered stone-like finish surface on a substrate, which has heretofore not been readily available, particularly as a standard building material. Use as a surface for walls or other panels for indoor or outdoor use, with finished surfaces ranging from a high-gloss, mirror-like smooth finish to a controlled, uniformly textured finish. intended to be adjusted.

It is therefore an object of the present invention to provide a new and improved low cost method for providing a man-made or simulated stone-like finish surface on a substrate that is superior to conventional simulated natural stone products and methods in feel and degree of simulation of natural stone. An object of the present invention is to provide a method and the resulting novel product. It is also an object to provide standard architectural panels for assembly, etc. with tailored finished surfaces ranging from high gloss surfaces to textured, embossed or patterned surfaces.

Other objects and further objects of the invention are set out below and more particularly pointed out in the claims.

[Means to solve the problem]

The present invention, viewed generally in one of its broad aspects, is a method of manufacturing a synthetic stone-like finish surface for attachment to a substrate, comprising: a flexible, uncured liquid synthetic resin binder; A mixture of a colored pigment, filler particles for the resin, and a curing agent is prepared, with one side of the mixture intended for attachment to a substrate; the other side of the mixture presenting a liquid surface of irregular, non-uniform particles. applying the mixture; applying successive portions of the irregular, non-uniform surface of the flexible, uncured liquid resin mixture to another surface (a flexible surface where a protective surface is desired for a finished surface); (like a thin plastic sheet)
together with corresponding successive portions of the material by means of roller application pressure. Other design modifications are discussed below as preferred products resulting from the method, including optimal modes and embodiments of the method.

〔Example〕

The invention will now be described with reference to the accompanying drawings.

Referring to FIG. 1A, a curable synthetic resin assemblage or mixture containing fine aggregate stone or like filler particles as described below, such as silica, etc. For the base material 3 consisting of
It is shown being applied as a thin layer 1 by means of a spray gun 5. Applying the fine aggregate and uncured liquid resin binder in a layer or coating mixture with a suitable curing agent to the substrate by any other suitable means, such as by troweling, brushing, or rolling. You can also.

Curable synthetic resin combinations useful in the practice of this invention and into which certain aggregate stones or like particles such as silica and the like are admixed include polyesters, epoxies,
It can have a urethane or cementitious base.

Although virtually any curable synthetic resin liquid coating material may be used, the preferred coating material is a polymerizable unsaturated polyester such as prepared from an ethylenically unsaturated polycarboxylic acid and a polyhydric alcohol. be. Such coating materials may also include copolymerizable ethylenically unsaturated compounds such as styrene to make the unsaturated polyester resin more flowable and to crosslink the resin upon curing. In a most preferred embodiment, the main component of the curable synthetic resin m-acid is PolyLite Φ polyester resin 33-031, sold by Lyhold Chemicals, Inc., Elizabeth, New Jersey. 33-031 is an unsaturated polyester resin of styrene monomer, which is thixotropic and has been previously promoted to cure at room temperature by the addition of methyl ethyl ketone peroxide. Its boiling point is approximately 146°C and its specific gravity is 25°C ()I! O-1) from 1.05 to 1.
It is 22. It is approximately 44 to 48% styrene monomer, and its viscosity is 350-550 cPs (6O
rpm).

A curable synthetic resin composition suitable for a specific application method and/or
Alternatively, thickeners may be added to the composition to provide a degree of shrinkage suitable for application to a particular surface. For example, trowel application typically requires a more concentrated composition than spray application. Also, upright surfaces require a more concentrated composition than horizontal surfaces. Compositions applied to upright surfaces will flow or drip and become porous if too thin. Generally, thickeners are added to obtain a composition that has a consistency that will not flow or sag after being applied onto a particular surface.

In the most preferred embodiment, B, E, T,
Specific surface area measured by method is 200±25rrf/g
CAB-0-SI, an amorphous pyrogenic silica of
L 8 M-5 pyrogenic silica is used as a thickener.

It may also be desirable to add one or more matrix fillers to the composition to reduce cost and/or alter the consistency of the composition. Matrix fillers are also used to modify the strength of the cured composition.

Preferably, the filler is finely divided and has an average particle size ranging from 10 to 325 particles.

These fillers include powdered talc, powdered quartz, fine silica, diatomaceous earth, gypsum, powdered glass, mineral clays such as china clay (kaolin), illite, powdered chalk, powdered marble, powdered limestone, aluminum silicate. , aluminum stearate, calcium silicate, galena, borax and aluminum trihydrate.
The last mentioned aluminium trihydrate is effective in increasing the flame retardancy of the final product and is preferred as a filler.

Fillers can also contribute to the color, clarity, and surface properties of the cured composition. Therefore, it is appropriate to use different fillers when imitating different types of stone. For example, when imitating marble, the general criterion for fillers is that they produce a translucent product when homogeneously mixed into the resin matrix. This provides depth to the product, which helps create a marbled appearance. The amount of filler and filler particle size also affect the translucency of the final product.

It may also be appropriate to dilute the composition with a solvent to bring it to a viscosity suitable for the method of application; for example, spraying requires a much less viscous product than troweling. Therefore, in order to obtain a viscosity suitable for spraying,
Solvent is added. This solvent is selected to be one that evaporates quickly. Solvents specifically employed for use in the present invention include acetone, methyl ethyl ketone, xylene, ethanol, and the like. Acetone is the preferred solvent.

Colored pigments can be added to the composition so that the color of the composition has the desired background color. The colored pigment is preferably an inert, inorganic, finely divided substance applied as a dry powder or paste. Such colored pigments are well known and readily available. Preferably, the colored pigment is a selected P, M, S, polymer dispersed pigment sold by PMnis Consolidated, Tummersett, New Jersey.

Finally, a polymerization catalyst or catalyst mixture is added to the composition. Such catalysts are well known in the art for curing without the production of external heat and are usually free radical catalysts based on peroxide type compounds, such as methyl ethyl ketone peroxide, benzoyl peroxide, Tertiary butyl hydroperoxide and the like. Typically, the catalyst is present in an amount ranging from about 0.1 to 6% by weight of the polyester resin.

A layer 1 of a finely particulate aggregate layer or a mixture of like particles and a synthetic resin composition is coated onto the substrate 3 before the composition is cured or crosslinked. The curing time will of course depend on which resin and catalyst are chosen for the synthetic resin composition. Compositions include wood, particleboard, sheetrock, beaverboard, “Masonit, e”
and compressed wood, commercially available under the trade names "Timblend", various compressed fiberboards, cardboard, paper, textile fabrics, plastic sheets, fiberglass, cement blocks, bricks, metals, and other common building materials. can be coated onto a wide variety of conventional flat or curved substrates, such as those described above.

According to a preferred application of the invention described herein:
This coating layer or thin layer 1 has a thickness of about 1.611 IIl for the inner wall of the panel surface, and 1.611 II for the outer wall as well.
It can be made very thin, about 6 mm.

According to the invention, while the mixture of fine aggregate layer or like particles and uncured resin binder is still liquid, flexible and uncured, the thin flexible molded film 7 of FIG. , are pressed together onto the rough and uneven outer or outer surface of the coated thin layer l. According to a preferred optimum mode embodiment, which is particularly suitable for highly finished, ie high gloss products, the thin film 7 has a thickness of 0.2
It is a smooth plastic sheet with a high gloss mirror surface, such as 5 mm clear polyethylene. 1st consecutive drawing
As shown in Figures C and 1D, a very important technique for applying a thin flexible film 7 to the outer irregular surface of the coated layer 1 is time-dependent. Illustrated consecutively. That is, successive sections of the thin film 7 from left to right in the drawing are successively pressed against corresponding successive sections of the irregular outer surface of the layer 1, such as by rollers 9. This crushes the coated resin and pigment particles and causes the layer l
It has been found that successive portions of the irregular outer surface of the thin flexible film 7 can be shaped or forced to conform to correspond substantially exactly to the finished surface of the inner surface 7' of the thin flexible film 7. Of course, this also means that the layer 1 of the uncured aggregate particle-resin binder coating can be applied to the substrate 3 (if it has porosity or irregularities, to aid in the attachment of the cured coating layer during crosslinking). It also puts pressure on the government. Thus, in the left-hand part of FIG. 1C, the portion of film 7 pressed against the left-most outer surface of layer 1 is smoothed, as indicated by lit 1 1'. During this continuous pressing process, a mirror-like smoothness is achieved by forced conformity of the highly glossy inner surface 7' of the thin film 7 with the finished surface.

This continues along layer 1 of the coating up to Figure 1D. The air between the film 7 and the layer 1 of the uncured composite coating will be evacuated so that the thin film remains sealed and pressed against the layer 1 of the coating and quickly Curing takes place.

Prior to application of the thin flexible film 7, a corresponding thin release layer is applied to the surface 7' of the film, such as by lightly spraying silicone or wax. Thus, once the layer 1 has cured and crosslinked, the panel consisting of the lamina 1 and the substrate 3 can be transported to a construction site for use as a wall, panel or other surface member, etc. A thin film 7 on the outside provides protection which acts as a barrier against scratches and provides protection when stacking, storing and transporting the product. Once the panel with the finished surface has been installed, the film 7 can be peeled off and then applied to the substrate with a high gloss mirror smooth finish on the outside of the inside surface of the film 7. An integrally attached hardened man-made masonry surface is left.

This technique allows the creation of relatively inexpensive man-made or imitation high-gloss stone surfaces without the expense of polishing, polishing, or other finishing steps required for natural stone, traditional cast or molded stone, etc. can be provided to The present invention can also be manufactured to be lightweight by selecting appropriate materials, which is also a most desirable feature.

If it is desired to obtain some pattern or texture or embossing on the outer surface of the finished surface, such a pattern or the like can be configured on the inner surface 7' of the thin film 7, thus produced according to the invention. This results in a corresponding pattern being molded into the cured outer finished surface of the product. Such a pattern is shown as the final finish of the partial product in FIG. 2B, which is different from the high gloss particulate pattern (eg, simulated granite) of FIG. 2A.

A preferred composition for making products such as the simulated stone of Figures 2A and 2B is as follows: epoxy resin (
(such as Reichhold Chemicals' DER331)
Part 1: Epoxy resin hardener with the trade name Versamed 140 Part A: Pyrogenic silica (Cabot's Cab
-0-Sil) 1 part; and 1% part of silica aggregate.

The colorant is used at approximately a teaspoonful per 8 liters (2 gallons) of the mixture to simulate some natural stone as the resin and particles are crushed by rolling.

If desired, the coating is also applied over the edges (not shown) of the substrate, and along wider areas, for example the narrow part of the edges, and if desired on the underside, and then Films can also be applied to simulate thick stone or cut rock.

The claimed invention further provides that a layer 1 of a mixture of a flexible, uncured liquid synthetic resin binder, a colored pigment, filler particles for the resin and a hardening agent is applied to a temporary surface of polyethylene or other sheet material. That is, it is applied to the base material 3,
A useful intermediate which can be kept in an uncured, pliable, liquid state in a refrigerator for later use by pressing across layer 1 of the coating (with or without shaped surface film 7) by means of rollers 9. It has been found that products can be obtained. Even at normal refrigeration temperatures (e.g. 4.4°C) and freezing temperatures (where the mixture remains pliable due to the absence of moisture), especially the previously mentioned pyrogenic silicas (e.g. Cabot's Cab-0-Sil) In the presence of , the effect of the above-mentioned curing agent is suppressed. Pyrogenic silica also acts as a set retarder (eg, 7 A parts to 2 parts resin).

When the user desires to apply the mixture to coat a permanent surface, the flexible, uncured, cooled mixture is removed from the refrigerator and applied to the permanent surface, forming a temporary substrate. 3 (and film 7 if used)
), and this mixture is rolled again (by roller 9) along the surface of the permanent substrate and, if desired, along the corners and edges, by means of a roller, preferably made of wood, to remove the hardening agent. Upon activation, it is automatically cured at room temperature as described above, thus providing the applied simulated stone coating or surface. Permanent surfaces may incidentally have all kinds of imperfections, i.e. cracks, holes, etc., but the present invention hides these and overlays them with a flexible uncured mixture. When transferring and rolling, small pieces may be rolled together or repairs may be made that cannot be detected. After curing, polishing or surface treatment can be carried out as desired, and successive layers can be applied, such as when the appearance of the finished surface is to be easily changed when desired. .

Further design modifications may be possible to those skilled in the art, including using other finishes or forming surfaces other than forming sheet film 7 for rolling the coating mixture; It is believed to be encompassed within the spirit and scope of the invention as defined by the claims.

〔Effect of the invention〕

In accordance with the present invention, there is provided a new and improved low cost method of providing a man-made or simulated stone-like surface on a substrate, and a resulting new product, which has the feel of natural stone. It is superior to conventional imitation natural stone products and methods in terms of quality and degree of imitation. Further, according to the present invention,
The finished surface can range from a highly glossy surface to a textured, embossed or T14-like surface. This makes it possible to provide standard construction panels for assembly easily and at low cost, but as mentioned above, such panels have not been easily available as construction materials until now. .

Thus, according to the present invention, various advantages are brought about, such as being able to easily obtain an imitation stone surface or an imitation stone product at a low cost, and also being able to store it as an intermediate product for a long period of time.

Finally, to provide a summary of the invention for ease of understanding, the present invention provides a novel artificial or simulated stone surface and method of manufacturing the same. This stone surface is formed from a liquid mixture of an uncured synthetic resin, a suitable filler, a colored pigment and a hardener, and is hardened with a finish corresponding to that of the inner surface of the molded surface, such as a thin flexible film. The surface of the substrate is attached to the substrate. The flexible film is pressed together with the resin mixture by rollers or the like, and is made airtight against the finished surface while the resin mixture is in a liquid state before curing. Also provided is an uncured mixture that is refrigerated for subsequent application to the substrate and is cured to form the surface finish after such application.

[Brief explanation of drawings]

Figures 1A to 1D are illustrations showing successive steps in the method of manufacturing the novel product of the present invention; Figures 2A and 2B are illustrations of a high gloss finish and a textured finish, respectively; FIG. 2 is a partial perspective view of an exemplary final product. 1--Layer 3--Base material 5--Spray gun 7--Film 7°...Surface 9- Roller

Claims (1)

[Scope of Claims] 1. A method for manufacturing a man-made stone-like finished surface attached to a substrate, comprising: a flexible, uncured liquid synthetic resin binder;
A mixture of a colored pigment, filler particles for the resin, and a curing agent is prepared; the mixture is applied to the substrate on one side and an irregular, non-uniform liquid resin surface on the other side. ;
Successive sections of irregular, non-uniform surfaces of a flexible, uncured liquid resin mixture are successively rolled by rolling pressure along with corresponding successive sections of a sheet having a uniformly finished inner surface. pressing, compressing the resin mixture and forcing it into correspondence with the inner surface of the sheet, while at the same time expelling air from between the two; in the compressed airtight state, the liquid resin mixture is curing; the sheet then functions to protect the finished surface until it is used, at which time a step of separating the sheet and the cured mixture is performed to cure the cured mixture resulting from compression of the resin mixture. A method comprising exposing a finished surface having a smooth engineered stone appearance and having said finish of said inner surface of the sheet. 2. A method for producing an artificial stone-like finished surface for attachment to a substrate, comprising preparing a mixture of a flexible, uncured liquid synthetic resin binder, a colored pigment, filler particles for the resin, and a hardening agent, one side of the mixture for attachment to the substrate;
Applying the mixture such that the other side of the mixture presents a liquid surface of irregular, non-uniform particles; a continuous portion of the irregular, non-uniform surface of a flexible, uncured liquid resin mixture successively pressed together with corresponding continuous portions of another uniformly finished surface by means of roller application pressure;
compressing the resin mixture to force the mixture throughout into correspondence with a continuous portion of said another surface while simultaneously expelling air between the two; in said compressed air-tight state by the action of said curing agent; curing the liquid resin mixture; separating the cured mixture and another surface, forming a finished surface having a hardened smooth engineered stone-like appearance resulting from compression of the resin mixture and having the finish of the other surface; A method consisting of exposing. 3. The uncured synthetic resin binder is selected from the group consisting of polymerizable unsaturated polyester resins, epoxy resins and urethane resins with or without styrene monomer; the filler particles are silica, powdered talc, powdered quartz, Group consisting of diatomaceous earth, gypsum, powdered glass, mineral clay, illite, powdered chalk, powdered marble, powdered limestone, aluminum silicate, aluminum stearate, calcium silicate, galena, borax and aluminum trihydrate. the colored pigment is selected from the group consisting of inert inorganic powders and pastes and polyester dispersible pigments; the curing agent is a free radical catalyst based on peroxide type compounds, methyl ethyl ketone peroxide, peroxide 3. The method of claim 2, wherein the polymerization catalyst is selected from the group consisting of benzoyl and tert-butyl hydroperoxide. 4. The artificial stone is intended to imitate smooth marble, and the filler is selected in an amount and particle size that is uniformly mixed within the resin binder and produces deep translucency after the resin is compressed. 3. The method according to claim 2. 5. The method of claim 2, wherein the finished surface of the cured mixture is integrally attached to the substrate on one side, covering one or more of the top surface, edges, and lower areas of the substrate. 6. An artificial stone-like finished surface produced by the method of claim 2 and integrally supported on a substrate. 7. The finished surface of a substrate-supported artificial stone material according to claim 6, wherein the finished surface is a type of high-gloss, patterned finished surface. 8. A polyester resin, a pigment dispersed in a polyester, which when uncured in liquid form is generally pressed against a high gloss smooth surface to conform to that high gloss smooth finish, and then cured and released against said surface. and an engineered stone-like finish surface consisting of a layer of a hardened mixture of aluminum trihydrate filler. 9 An artificial stone-like finished surface attached to one or more of the upper surface, edges and lower regions of a substrate, which initially contains uncured, flexible and liquid synthetic resin binder, colored pigments and filler particles. and a curing agent, said resin selected from the group consisting of polymerizable unsaturated polyester resins, epoxy resins and urethane resins with or without styrene monomer; said colored pigment; is selected from the group consisting of inert inorganic powders and pastes and polyester dispersible pigments; said filler particles are selected from the group consisting of powdered silica, silicates, quartz, diatomaceous earth, clay and aluminum trihydrate; The layer or layers of the cured mixture are pressed while liquid and uncured, compressed against a high gloss smooth surface to conform to the smooth finish of the surface, and then cured throughout and released against the surface. An artificial stone-like finish surface made of 10 A method for producing an artificial stone-like finished surface for attachment to a substrate, comprising a flexible, uncured liquid synthetic resin binder and coloring for final attachment to a permanent substrate. A mixture of pigment, filler particles for the resin, and hardener is prepared; the mixture is applied to a temporary substrate so as to present a liquid surface of irregular, non-uniform particles; successive portions of the irregular, uneven surface of the liquid resin mixture are successively pressed together by roller pressure against a temporary substrate; the mixture is maintained in a cooled state, such as by refrigeration; the mixture is kept pliable and uncured by inhibiting curing until it is removed from the cooled state and applied to a permanent substrate. 11. The method of claim 10, wherein upon removal from the cooling state, the mixture applied to the permanent substrate is rolled onto the substrate and then hardened by the action of the hardening agent. Method. 12. The method of claim 11, wherein the temporary substrate is peeled from the mixture before curing. 13. The uncured synthetic resin binder is selected from the group consisting of polymerizable unsaturated polyester resins, epoxy resins and urethane resins with or without styrene monomer; the filler particles are silica, powdered talc, powdered quartz, Group consisting of diatomaceous earth, gypsum, powdered glass, mineral clay, illite, powdered chalk, powdered marble, powdered limestone, aluminum silicate, aluminum stearate, calcium silicate, galena, borax and aluminum trihydrate. the colored pigment is selected from the group consisting of inert inorganic powders and pastes and polyester dispersible pigments; the curing agent is a free radical catalyst based on peroxide type compounds, methyl ethyl ketone peroxide, peroxide 13. The method of claim 12, wherein the polymerization catalyst is selected from the group consisting of benzoyl and tert-butyl hydroperoxide. 14 Comprising a mixture of a flexible, uncured liquid synthetic resin binder, a colored pigment, filler particles for the resin, and a curing agent,
An artificial stone-like finish surface preparation for storage in an uncured state under refrigeration, which has been compressed and crushed in its entirety against a temporary substrate. 15. The artificial stone-like finish surface preparation of claim 14, consisting of a polyester resin, a polyester dispersible pigment, and an aluminum trihydrate filler. 16 the uncured flexible liquid synthetic resin is selected from the group consisting of polymerizable unsaturated polyester resins, epoxy resins and urethane resins with or without styrene monomer;
the colored pigment is selected from the group consisting of inert inorganic powders and pastes and polyester dispersible pigments; the filler particles are selected from the group consisting of powdered silica, silicates, quartz, diatomaceous earth, clay and aluminum trihydrate. 15. The artificial stone-like finish surface preparation of claim 14.