JPH04280884A - Artificial stone - Google Patents

Abstract

PURPOSE:To provide a light-weight artificial stone having high strength and small thermal expansion coefficient. CONSTITUTION:The objective stone is produced by compounding a filter- containing artificial stone main raw material with particles having a color different from the color of the filter, dispersing 5-30 pts.wt. of a light-weight filler in 100 pts.wt. of the obtained mixed slurry and curing the dispersion. As an alternative method, granules free from pigment is dispersed in the artificial stone main material containing a filler and a pigment, 3-50 pts.wt. of a light-weight filler is dispersed in 100 pts.wt. of the obtained mixed slurry and the dispersion is cured. Since the stone contains the light-weight filler in an amount of the above range, the weight of the stone can be reduced and the reliability of the strength of the stone can be improved. The stone can be fixed with a machine screw, etc. The thermal expansion coefficient is lowered by the decrease of the amount of the resin.

Description

[Detailed description of the invention]

0001

[Industrial Application Field] The present invention relates to natural stone-like artificial stones such as granite-like artificial stones and artificial marbles used for building materials such as sink counters, wall panels, floor panels, etc., and particularly relates to lightweight artificial stones. Regarding stones.

0002

[Prior art] Conventionally, wash counters, wall panels,
Artificial stones such as granite-like artificial stone and artificial marble are widely used as building materials for floor panels and the like. As such natural stone-like artificial stones, for example, those described in Japanese Patent Publication No. 62-22939 have been proposed. The artificial stone described in this publication has a grain size of approximately 1 to 3 m as a material for artificial stone.
A pigment is attached to the surface of natural stone or mineral slag, and this is hardened and molded by mixing a filler such as aluminum hydroxide with a resin. However, many of these artificial stones have a specific gravity of about 1.8 to 2.0, which not only makes handling extremely inconvenient and has poor workability, but also has a high coefficient of thermal expansion due to the high proportion of resin. Therefore, in order to overcome these drawbacks, a lightweight artificial stone disclosed in Japanese Patent Application Laid-Open No. 2-74577 has been proposed. The artificial stone described in this publication is made by adding an inorganic foam such as pearlite to a resin and kneading the mixture, which is then hardened, and a synthetic resin layer is formed on the surface layer.

0003

[Problems to be Solved by the Invention] However, since the above-mentioned artificial stone is simply a mixture of resin and inorganic foam and then hardened, it is extremely unreliable in terms of strength, and for example, it cannot be used with screws or the like. Not only can it not be fixed, but natural lightweight materials such as pearlite have no whiteness, so it cannot be made to look like natural stone unless a gel coat layer or the like colored in a predetermined color is formed on the top surface.

Therefore, the present invention was proposed in view of the above-mentioned problems with conventional artificial stones, and is lightweight, has excellent strength, has a low coefficient of thermal expansion, and furthermore The purpose is to provide an artificial stone that looks like natural stone and has an excellent heat insulating effect.

[0005]

[Means for Solving the Problems] The present invention has been proposed to achieve the above-mentioned objects, and the first invention is to provide a filler-containing material in the main material of an artificial stone containing the filler. It is characterized by being made by dispersing granules of a different color from the material, and by mixing 5 to 30 parts by weight of a lightweight filler into 100 parts by weight of a mixed slurry consisting of the above-mentioned main material and granules and curing the mixture. In the second invention, granules are dispersed in the main material of the artificial stone containing a filler and a pigment, and based on 100 parts by weight of a mixed slurry consisting of the main raw material and the granules, It is characterized by being mixed with 5 to 30 parts by weight of a lightweight filler and hardened.

[0006] The above-mentioned filler may be one that has been commonly used in the past, and preferably one that has a refractive index similar to that of the resin, such as aluminum hydroxide, aluminum silicate, or glass frit. . By using a substance with a refractive index similar to that of resin as a filler, it is possible to give the manufactured artificial stone a certain degree of translucency, and if particulate matter is mixed in, it is possible to Since the granular pattern allows not only the surface but also the granules contained inside near the surface to be seen through, it can exhibit a high-quality texture with a three-dimensional effect that is even closer to that of natural stone. Of course, the above-mentioned filler may include not only these substances but also other substances such as calcium carbonate, or may be used by appropriately blending these substances. In addition, the particle size of these fillers should be set to 2 if the artificial stone to be manufactured has a deeper depth.
A material in the range of 0 to 70 μm is used, but generally 5 to 70 μm.
It is sufficient to use a material with a thickness in the range of 100 μm.

[0007]Although various conventionally used pigments may be used as the above-mentioned pigments, when granules are mixed into the slurry described later, the pigments attached to the surface of the particles of the filler may dissolve or disperse. In order to prevent this, it is preferable to use inorganic pigments. Furthermore, various colors of pigments may be used depending on the type of artificial stone to be manufactured, or multiple types of granules to which pigments of different colors are added may be used at the same time. , at least a color different from that of the filler is used. In addition, in the present invention, this pigment is not only added when producing the above-mentioned granules, but may also be used only when producing a slurry described below. In other words, since the natural stone-like pattern is created by the relative combination of the color of the main material containing the filler and the color of the granules, pigments are added when making the granules, while pigments are added when making the slurry. There are two cases: a case where the pigment is not added, and a case where the pigment is added at the time of preparing the slurry without adding the pigment when producing the granules.

[0008] The binder used when producing granules from the above-mentioned filler and pigment is P.
VA (polyvinyl alcohol), linseed oil, water glass, etc. are used. Further, the particle size of this granular material may be appropriately determined depending on the type of artificial stone to be produced. For example, in the case of producing a granite-like artificial stone, the average particle diameter is 0.
It may be 5 to 2.0 mm.

[0009] Then, the colored granules as described above are mixed with a slurry made of a mixture of a filler and a resin, a lightweight filler is added to the slurry, and the mixture is filled into a predetermined mold. and harden. Further, as the resin used when producing the slurry, unsaturated polyester resin, acrylic resin, etc. are used. In addition, in the process of manufacturing the artificial stone according to the present invention, when mixing the above-mentioned fillers, resins, granules, and lightweight fillers and filling them into a mold and curing them, benzoyl peroxide, methyl ethyl ketone peroxide, etc. Using a common peroxide-based curing agent,
If necessary, a curing accelerator such as cobalt naphthenate is used in combination. Curing is performed at room temperature and if necessary at approximately 50°C.
It is preferable to apply heat to ~80°C.

In the present invention, the lightweight filler is added in an amount of 5 to 30 parts by weight to 100 parts by weight of the mixed slurry of resin, filler, and granules. Here, it is sufficient that the above-mentioned lightweight filler is added in the necessary amount to reduce the specific gravity, but if the light-weight filler is added excessively to the amount of the slurry, the strength of the artificial stone will decrease, so there is an upper limit. should be set with this point in mind. Considering this point, it is preferable to set the lightweight filler to 5 to 30 parts by weight, for example, with respect to 100 parts by weight of the mixed slurry. As for the type of lightweight filler, plastic foams such as foamed polyurethane resin, foamed polystyrene resin, and foamed phenol resin can be used, but from the viewpoint of economy, silica balloons, perlite, olivine, and pearl can be used. Preferably, inorganic foams such as sand, volcanic sand such as whitebait are used.

[0011]

[Function] According to the artificial stone of the present invention, the colored or non-colored granules and lightweight filler are dispersed and hardened into the main material of the artificial stone containing a filler, so it is lightweight. Not only can it be easily transported, it can also improve its heat insulation properties, and since the occupancy of the resin contained therein is reduced, it can also suppress the harmful effects of thermal expansion.

Furthermore, in the present invention, the above-mentioned lightweight filler comprises:
Since it is made by adding 5 to 30 parts by weight to 100 parts by weight of the above mixed slurry and curing it, it not only achieves weight reduction as mentioned above, but also has high reliability in terms of strength. be able to. Furthermore, in the present invention, since the natural stone-like color tone or pattern is created by the relative relationship between the color of the granules and the color of the material other than the granules, there is no need to separately form a colored gel coat layer. .

[0013]

[Examples] Specific examples of the present invention will be described in detail below along with comparative examples.

Example 1 0.5 parts by weight of 0.6% cobalt naphthenate and 1 part by weight of methyl ethyl ketone peroxide were added to 50 parts by weight of unsaturated polyester having a viscosity of 800 cps.
65 parts by weight of aluminum hydroxide with an average particle size of 30 μm and 10 parts by weight of colored granules with an average particle size of 1 mm were added and thoroughly mixed using a stirrer to prepare a slurry composition. Note that the viscosity of this slurry composition was 35.000 cps. Then, 15 parts by weight of pearlite having an average particle size of 0.5 mm was added as a lightweight filler to the slurry composition thus prepared, and the mixture was thoroughly mixed to prepare a molding material. Next, the obtained molding material was coated with a transparent gel coat containing a curing accelerator, cast into a gelled resin mold, cured at room temperature, removed from the mold, and cured at 70°C for 1 hour. Granite-like artificial stone A was obtained by ringing.

Comparative Example 50 parts by weight of unsaturated polyester with a viscosity of 800 cps, 80 parts by weight of aluminum hydroxide with an average particle size of 30 μm, and 1 colored particulate part with an average particle size of 1 mm.
0 parts by weight was added and thoroughly mixed using a stirrer to prepare a slurry composition. Note that the viscosity of this slurry composition was 28.000 cps. Then, the slurry composition thus prepared was cast into a resin mold without adding a lightweight filler, cured at room temperature, and then removed from the mold.
Granite-like artificial stone X was obtained by curing at °C for 1 hour.

Specific gravity and bending strength (Kgf/cm2) for each of the granite town artificial stones A and X obtained by the method described above.
, Barcol hardness were measured, and the values listed in Table 1 below were obtained.

[0017]

[Table 1]

As is clear from the results listed in Table 1 above, there is no difference in bending strength (Kgf/cm2) and barcol hardness between granite-like artificial stones A and X. Regarding the specific gravity, the granite-like artificial stone A obtained in the example is much smaller than the granite-like artificial stone X obtained in the comparative example, and it can therefore be understood that the weight is sufficiently reduced.

[0019]

Effects of the Invention As is clear from the description of the above embodiments, according to the artificial stone according to the present invention, the colored or uncolored granules are contained in the main material of the artificial stone containing a filler. Since the lightweight filler is dispersed and hardened, it is not only lightweight and can be easily transported, but also improves heat insulation and reduces the percentage of resin contained in it, so it can be easily transported due to thermal expansion. Harmful effects can also be suppressed.

Furthermore, in the present invention, the lightweight filler is
Since it is made by adding 5 to 30 parts by weight to 100 parts by weight of the mixed slurry and curing it, it not only achieves weight reduction as mentioned above, but also has high reliability in terms of strength. Can be done. Therefore, it can be fixed using fixing means such as screws, and together with the above-mentioned weight reduction, workability can be further improved. Furthermore, in the present invention, the natural stone-like color tone or pattern is created by the relative relationship between the color of the granules and the color of the material other than the granules, so there is no need to separately form a colored gel coat layer. It can be manufactured easily and quickly.

Claims (2)

[Claims] Claim 1: The main material of the artificial stone containing a filler is dispersed with granules having a color different from that of the filler, and the amount of the artificial stone is 100 parts by weight of a mixed slurry consisting of the main material and the granules. An artificial stone characterized by being hardened and mixed with 5 to 30 parts by weight of a lightweight filler. [Claim 2] Particulate matter is dispersed within the main material of the artificial stone containing a filler and a pigment, and
An artificial stone characterized in that 5 to 30 parts by weight of a lightweight filler is mixed into 100 parts by weight of a mixed slurry consisting of the above main material and granules and then hardened.