JPH04254456A - Artificial marble and production thereof - Google Patents

Abstract

PURPOSE:To provide the artificial marble like natural granite which eliminates the drawbacks intrinsic to the conventional artificial marble, allows easy grinding and polishing of the surface, has an excellent stone-like feel, can be imparted with arbitrary patterns and shapes and has reliability. CONSTITUTION:This artificial marble is produced by putting a liquid matrix resin, which is compounded with coarsely crushed particles of a curing resin having the sp. gr. larger than the sp. gr. of the liquid matrix resin, into a forming mold, then curing and solidifying the matrix resin after allowing the coarsely crushed grains to settle, taking the molding out of the forming mold, and subjecting the molding to a finishing treatment by grinding, polishing, etc.

Description

[Detailed description of the invention]

0001

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a new artificial marble and a method for producing the same. More specifically, the present invention relates to an artificial marble having a natural granite-like stone texture and a method for easily producing the same.

0002

[Prior Art] Natural granite is a type of granite whose main components are quartz and feldspar, which also contain mica, pyroxene, amphibole, etc. The color tone is mainly controlled by the color of feldspar, and depending on the color, white It is called Mikage, Black Mikage, Peach (Sakura) Mikage, and Rusty Mikage, and depending on the size of the crystal grains, it is also called Omikage, Medium Mikage, Komikage, etc. When polished, it becomes shiny and beautiful mottled, striped, and marble patterns appear. These natural granites are widely used as building materials, civil engineering materials, tombstones, decorations, etc., but they have drawbacks such as being hard, heavy, and high strength, making them difficult to process, expensive, and difficult to obtain. There is. In order to cover up these drawbacks of natural granite, natural stone particles with a particle diameter of several mm or less to several mm, or even about 50 mm, are placed in a casting resin, and after hardening, the surface is hardened. A particle size of several meters is contained in ground and polished artificial stone or casting resin.
After putting in the crushed material of hardened resin of m or less and hardening it,
Artificial stones with ground and polished surfaces are available, but
The former has disadvantages such as poor adhesion between the resin for casting and the stone granules, making it unreliable, the hardness of the stone granules making it difficult to grind and polish the surface, and the inability to form arbitrary patterns or shapes. can be,
The latter has a poor stone texture, and even if the surface is ground and polished, the crushed particles of hardened resin in the casting resin with a particle size of several mm or less are difficult to expose on the surface, and even if they are exposed on the surface, they are difficult to see, so it is difficult to see. It has shortcomings such as poor visual performance, and improvements are needed.

0003

[Problems to be solved by the invention] Conventional artificial stones are unreliable, the surface of the molded product is difficult to grind and polish, the stone texture is poor, and arbitrary patterns and shapes cannot be formed, so natural granite Artificial stones of this color were not obtained. To provide an artificial marble having a natural granite-like stone texture and a method for easily producing the same.

0004

[Means for Solving the Problems] As a result of extensive research by the present inventors in order to solve the conventional problems, the first object of the present invention is to easily grind and polish the surface of a molded product; To provide a granite-like artificial marble with excellent stone texture, arbitrary patterns and shapes, and reliability. A second object of the present invention is to provide a method for easily manufacturing artificial marble having a natural granite-like stone texture.

The invention of claim 1 of the present invention is an artificial marble having a flat surface made of a composition of coarsely ground particles of a cured or solidified resin and a matrix resin, wherein the coarsely ground particles are distributed from the inside to the surface layer. Granite-like artificial marble is characterized by a large amount of coarsely ground particles contained in the surface layer and at least a part of which is exposed on the surface. A second aspect of the present invention is the granite-like artificial marble according to the first aspect, wherein the cured or solidified resin and the matrix resin are thermosetting resins or thermoplastic resins.

The third aspect of the present invention is a method for producing granite-like artificial marble comprising the following steps. 1. The matrix resin mixed with coarsely pulverized particles of a cured or solidified resin having a higher specific gravity than the liquid or molten matrix resin is placed in a mold. 2. While or after settling the coarsely ground particles, 3. The matrix resin is cured and/or solidified. 4. Remove the molded product from the mold. 5. Finish the surface of the molded product. The invention according to claim 4 of the present invention is a method for manufacturing granite-like artificial marble comprising the following steps. 1. A liquid or molten matrix resin containing coarsely ground particles of a cured or solidified resin is placed in a mold. 2. Then or at the same time, a liquid or molten matrix resin containing the coarsely ground particles at a lower density than the above density or the coarsely ground particles is used so that the matrix resin containing the coarsely ground particles at a high density is in contact with the inner surface of the mold. A liquid or molten matrix resin containing no additives is placed in a mold. 3. Curing and/or solidifying the matrix resin. 4. Remove the molded product from the mold. 5. Finish the surface of the molded product. The invention according to claim 5 of the present invention is a method for manufacturing granite-like artificial marble comprising the following steps. 1. A surface layer molded from a liquid or molten matrix resin containing coarsely pulverized particles of a cured or solidified resin at a high density is blended with a liquid or molten matrix resin containing fewer coarsely pulverized particles than the density, or a surface layer formed from a liquid or molten matrix resin containing coarsely pulverized particles of a hardened or solidified resin at a higher density. Laminated onto molded parts made from liquid or molten matrix resin. 2. If the surface of the above layer is not finished,
Perform finishing treatment.

The coarsely pulverized particles of cured or solidified resin used as the material for the granite-like artificial marble of the present invention are those obtained by coarsely pulverizing the cured or solidified material of thermoplastic resin and/or thermosetting resin. be. What is the cured product here?
A resin is cured as it is or with a crosslinking agent or crosslinking aid at room temperature or by heating, or by irradiating it with radiation such as ultraviolet rays. It is solidified. Thermoplastic resins include polyolefins such as polyethylene and polypropylene, polyester, polyamide, polycarbonate, polyoxymethylene, polyphenylene sulfide, and A.
BS, polystyrene, polyurethane, acrylic resin,
Examples include vinyl chloride resin, but are not particularly limited. Examples of thermosetting resins include unsaturated polyesters, epoxy resins, phenol resins, melamine resins, acrylic resins, urea resins, and allyl resins, but are not particularly limited.

However, those having good adhesion to the matrix resin and having a melting point higher than that of the matrix resin are preferably used. Moreover, those having a specific gravity larger than that of a liquid or molten matrix resin (abbreviated as liquid matrix resin) are also preferably used. In order to make the specific gravity of the coarsely pulverized particles larger than the specific gravity of the liquid matrix resin, it is necessary to select a material whose specific gravity itself is greater than the specific gravity of the liquid matrix resin, or to use calcium carbonate, talc,
It may be made by appropriately blending a filler with a large specific gravity such as a glass filler, aluminum hydroxide, metal powder, or ceramic powder.

The average particle diameter of the coarsely ground particles of the hardened or solidified resin used as the material for the granite-like artificial marble of the present invention is about 2 mm to 50 mm. If the average particle size is about 2 mm or less, the stone texture will be poor as mentioned above, and even if the surface of the molded product is ground or polished, it will be difficult for the particles to be exposed to the surface, and even if they are exposed to the surface, it will be difficult to see, so This is not preferable because the appearance will be poor. Moreover, if the average particle size is about 50 mm or more, the granite tone will be impaired, which is not preferable. The particle size distribution of the coarsely pulverized particles can be arbitrarily changed as long as the average particle size is within the range of about 2 mm to 50 mm, and the amount, shape or color of the coarsely pulverized particles, and even the pattern of the coarsely pulverized particles themselves can be changed as appropriate. By combining these as necessary, a variety of granite-like artificial marbles with different appearances, patterns, colors, and stone textures can be obtained.

As the matrix resin used as the material for the granite-like artificial marble of the present invention, the above-mentioned thermoplastic resins and thermosetting resins can be used. Among these, thermoplastic resins include polyester, polyamide, A
Examples of thermosetting resins such as BS, polystyrene, polyurethane, and acrylic resins include unsaturated polyesters, epoxy resins, phenolic resins, melamine resins, acrylic resins, urea resins, and allyl resins. , but is not particularly limited to these. However, those having good adhesion to the above-mentioned coarsely pulverized particles are preferably used. Moreover, those having a specific gravity smaller than that of coarsely pulverized particles are also preferably used. For this purpose, it is a preferred embodiment to use materials of the same type for the matrix resin and the coarsely ground particles.

When a thermoplastic resin is used as the matrix resin, it can be easily molded by known molding methods such as injection molding, extrusion molding, compression molding, and transfer molding. When used, it can be easily molded by known molding methods such as injection molding, extrusion molding, compression molding, transfer molding, and cast molding. The artificial marble of the present invention is an artificial marble having a flat surface made of a composition of the coarsely crushed particles and the matrix resin, wherein the coarsely crushed particles are contained more in the surface layer than in the interior, and At least a portion of the coarsely ground particles contained are exposed on the surface. With this configuration, the surface of the molded product can be easily ground and polished, and the surface can be easily given a desired finish such as gloss, and the coarsely ground particles and the matrix resin can be easily ground and polished. By appropriately combining them, or by appropriately devising the molding method, it is possible to have any color, pattern or shape, and since the coarsely pulverized particles have good adhesion with the matrix resin, they are highly reliable and It becomes a granite-like artificial marble with an excellent stone texture.

The first method for producing the granite-like artificial marble of the present invention is the production method consisting of the following 1 to 5. 1. A liquid matrix resin containing coarsely pulverized particles of a cured or solidified resin having a higher specific gravity than the liquid matrix resin is placed in a mold. 2. While or after settling the coarsely ground particles, 3. The matrix resin is cured and/or solidified. 4. Remove the molded product from the mold. 5. Finish the surface of the molded product. This manufacturing method will be explained in detail with reference to FIG. First, as mentioned above, the resin itself is a liquid matrix resin 3.
Coarsely pulverized particles 2 obtained by coarsely pulverizing by a known method a cured or solidified resin having a higher specific gravity or a resin having a higher specific gravity than the liquid matrix resin 3 by blending a filler with the resin, etc. Mix 4 with the casting resin of the matrix resin 3 and cast into the mold 1 (5). In this example, the bottom 1' of the inner surface of the mold 1 is in contact with the surface 7' of the molded article 7. Since the coarsely pulverized particles 2 settle due to the difference in specific gravity, the liquid matrix resin 3 is hardened and solidified while or after settling (6). By doing so, more coarsely pulverized particles 2 are contained in the surface layer of the molded article 7 than in the interior thereof. Next, the molded product 7 is taken out from the mold 1, and the surface 7' of the molded product 7 is surface-treated by a method such as grinding or polishing to expose at least a portion of the coarsely pulverized particles 2 from the surface. Obtain 8 marbles.

The second method for producing the granite-like artificial marble of the present invention is the production method consisting of the following steps 1 to 5. 1. A liquid matrix resin containing coarsely pulverized particles of hardened or solidified resin is placed in a mold. 2. Then or simultaneously, blending a liquid matrix resin containing coarsely ground particles at a lower density than the above density or blending the coarsely ground particles so that the matrix resin containing the coarsely ground particles at a high density is in contact with the inner surface of the mold. The untreated liquid matrix resin is placed in a mold. 3. Curing and/or solidifying the matrix resin. 4. Remove the molded product from the mold. 5. Finish the surface of the molded product. In this method, the coarsely pulverized particles may have a specific gravity greater than, the same as, or less than the liquid matrix resin. The coarsely pulverized particles are mixed with a liquid matrix resin at a high density to a density similar to that of the coarsely pulverized particles in the surface layer of the molded article described in the first method, and the mixture is placed in a mold. Next, while maintaining the state in which the liquid matrix resin containing coarsely ground particles at a high density is in contact with the inner surface of the mold, the same or different liquid matrix resin or coarsely ground powder containing coarsely ground particles at a lower density than that of the above-mentioned liquid matrix resin is then added. The same or different liquid matrix resin without particles is placed in a mold. Curing and solidifying the matrix resin.

Next, in the same manner as in the first method, the molded product is removed from the mold, and the surface of the molded product is treated by grinding, polishing, etc., so that at least a portion of the coarsely ground particles are exposed from the surface. In this way, the artificial marble of the present invention is obtained. A liquid matrix in which coarsely ground particles are mixed with a liquid matrix resin at a high density is put into a mold, and at the same time it is kept in contact with the inner surface of the mold, and the coarsely ground particles are blended in a smaller amount than the density. A method may also be used in which a liquid matrix resin containing no resin or coarsely pulverized particles is placed in a mold. Specific molding methods include, but are not limited to, multilayer injection molding, multilayer cast molding, and multilayer extrusion molding. According to this method, the coarsely pulverized particles may be allowed to settle, but since they do not need to be allowed to settle, production efficiency can be increased.

The third method for producing the granite-like artificial marble of the present invention is a production method consisting of the following 1-2. 1. A surface layer molded from a liquid matrix resin containing coarsely ground particles of a cured or solidified resin at a high density is blended with the same or different matrix resin or the coarsely ground particles containing less of the coarsely ground particles than the above density. It is then laminated onto a molded article made from the same or different matrix resin that has not been used. 2. If the surface of the above layer is not finished,
Perform finishing treatment. The coarsely crushed particles are blended into a liquid matrix resin at a high density to a density similar to that of the coarsely crushed particles in the surface layer of the molded article described in the first method above, and the surface layer is pre-molded, and the coarsely crushed particles are separately molded. This is a method in which the resin is laminated onto a molded product made from a liquid matrix resin or the like that does not contain the following. As a laminating method, a method using an adhesive, a melt bonding method, and other known methods can be used. Next, if the surface of the surface layer has not been subjected to finishing treatment, finishing treatment is performed. The surface layer may be finished before being laminated. According to this method, the coarsely ground particles may be allowed to settle, but they do not need to be settled.
It is also possible to mold the surface layer separately and finish the surface in advance, increasing manufacturing efficiency.

In the present invention, a crosslinking agent, a crosslinking aid, an organic or inorganic filler, an antioxidant,
A lubricant, an organic or inorganic pigment, an ultraviolet inhibitor, a dispersant, a neutralizing agent, a plasticizer, a nucleating agent, etc. can also be added within a range that does not impede the properties of these resins. Furthermore, the finishing treatment in the present invention includes, but is not particularly limited to, surface smoothing treatment by mechanical processing such as grinding and polishing, painting treatment such as gel coating, and combinations thereof.

[0017]

[Examples] Next, the present invention will be specifically explained by examples, but the present invention is not limited to these examples. (Example 1): Artificial marble of the present invention was produced by the method shown in FIG. A cured product was obtained by adding 0.03% by weight of benzoyl peroxide as a catalyst and 0.01% by weight of a black pigment to a methyl methacrylate polymerizable syrup containing 30% by weight of methyl methacrylate homopolymer or copolymer. This cured product was coarsely crushed using a crusher to produce coarsely crushed particles with an average particle size of 10 mm. The same syrup was mixed with 0.01% by weight of the gray pigment and 10% by weight of the same coarsely ground particles, and poured into a mold (length 30cm x width 30cm x depth 10cm), and the coarsely ground particles were allowed to settle. The syrup mixture was allowed to harden and solidify. Next, the molded product was removed from the mold, and the surface containing more coarsely ground particles than the inside of the molded product was ground and polished to expose a portion of the coarsely ground particles from the surface to obtain artificial marble. This artificial marble is easy to grind and polish the surface of the molded product, has a glossy surface, has a black pattern in the gray matrix resin, and has a granite-like appearance with an excellent stone texture. It was made of artificial marble. Furthermore, since the adhesiveness between the coarsely pulverized particles and the matrix resin was good, reliability was also excellent.

(Example 2): The syrup used in Example 1 was mixed with 0.01% by weight of the gray pigment and 20% by weight of the coarsely ground particles used in Example 1, and a mold (length 30 cm x
30cm wide x 10cm deep) and cast to a depth of 5cm.
Semi-hardened. Next, add only gray pigment to the same syrup.
．． 01% by weight and the remaining depth of 5cm in the same mold.
After casting by m, it was immediately hardened and solidified. The molded product was taken out of the mold, and the surface containing the coarsely ground particles was ground and polished to expose a portion of the coarsely ground particles from the surface to obtain artificial marble. This artificial marble was a granite-like artificial marble having an excellent stone texture similar to that of Example 1. (Example 3): No gray pigment in the syrup used in Example 1
．． 01% by weight and the coarsely ground particles used in Example 1 were
Mix % by weight and mold into a mold (length 30cm x width 30cm x
10cm deep) to a depth of 5cm and hardens immediately.
After solidification, it was removed from the mold, and the surface was ground and polished to expose a portion of the coarsely ground particles from the surface, creating a surface layer of artificial marble. Add only gray pigment to the same syrup.
01% by weight was mixed and injected into the same mold to a depth of 5 cm, and immediately hardened and solidified. After the molded product was taken out from the mold, the above surface layers were adhered and laminated to obtain an artificial marble. This artificial marble was a granite-like artificial marble having an excellent stone texture similar to that of Example 2.

[0019]

[Effects of the Invention] The present invention provides an artificial marble having a natural granite-like stone texture and a method for producing the same. The artificial marble of the present invention is an artificial marble having a flat surface made of a composition of coarsely crushed particles of a cured resin and a matrix resin, in which the coarsely crushed particles are contained more in the surface layer than in the interior,
Moreover, since some of the coarsely ground particles contained in the surface layer are exposed on the surface, the surface can be easily ground and polished, has an excellent stone texture, and can be given any pattern or shape. This is a reliable granite-like artificial marble. A liquid matrix resin containing coarsely pulverized particles of cured or solidified resin with a higher specific gravity than the liquid matrix resin is placed in a mold, the coarsely pulverized particles are allowed to settle, the matrix resin is cured and solidified, and the resin is molded from the mold. Take things out and grind them.
It can be made by finishing the surface by polishing, etc.

[Brief explanation of the drawing]

FIG. 1 is a diagram illustrating the artificial marble of the present invention and one method of manufacturing it.

[Explanation of symbols]

1 Molding mold 1' Bottom of molding mold 2 Coarsely pulverized particles of cured resin 3 Matrix resin 4 Mixture of coarsely pulverized particles and matrix resin 5
Casting into a mold 6 Sedimentation of coarsely pulverized particles and curing and solidification of matrix resin 7 Molded product 7' Surface of molded product 8 Artificial marble of the present invention

Claims (5)

[Claims] 1. An artificial marble having a flat surface made of a composition of coarsely ground particles of a cured or solidified resin and a matrix resin, wherein the coarsely ground particles are contained more in the surface layer than in the interior, and furthermore, the surface layer contains more coarsely ground particles than in the interior. An artificial marble characterized in that at least a part of the coarsely ground particles contained therein are exposed on the surface. 2. The artificial marble according to claim 1, wherein the cured or solidified resin and the matrix resin are thermosetting resins or thermoplastic resins. 3. A method for producing artificial marble comprising the following steps. 1. The matrix resin mixed with coarsely pulverized particles of a cured or solidified resin having a higher specific gravity than the liquid or molten matrix resin is placed in a mold. 2. While or after settling the coarsely ground particles, 3. The matrix resin is cured and/or solidified. 4. Remove the molded product from the mold. 5. Finish the surface of the molded product. 4. A method for producing artificial marble comprising the following steps. 1. A liquid or molten matrix resin containing coarsely ground particles of a cured or solidified resin is placed in a mold. 2. Then or at the same time, a liquid or molten matrix containing the coarsely ground particles at a lower density than the density, or a liquid or molten matrix resin containing the coarsely ground particles at a high density, is in contact with the inner surface of the mold. Put the resin into a mold. 3. Curing and/or solidifying the matrix resin. 4. Remove the molded product from the mold. 5. Finish the surface of the molded product. 5. A method for producing artificial marble comprising the following steps. 1. A surface layer molded from a liquid or molten matrix resin containing coarsely pulverized particles of a cured or solidified resin at a high density is molded from a liquid or molten matrix resin containing fewer or no coarsely pulverized particles than the density. layer on the molded product. 2. If the surface of the above layer is not finished,
Perform finishing treatment.