JPH0437666A - Production of ornamented porous material - Google Patents

Abstract

PURPOSE:To obtain the material which has the excellent luster and feeling in handling intrinsic to natural stones, is hardly stickable with stains and is hardly slippable even when wet with water, by laying inorg. granular substances mixed with a curable resin liquid on the surface of a leaf or flaky stone material coated with the curable resin liquid, and molding the material under pressurization. CONSTITUTION:The leaf or flaky stone material coated with the curable resin liquid is disposed on a forming mold surface and the inorg. granular substances mixed and wetted with the curable resin liquid are laid thereon, and are molded under pressurization. The porous material which is flatly and surely disposed with the leaf or flaky stone material and is ornamented like natural stones is obtd., without generating such large ruggedness as to be accumulated with the stains on the surface according to this method. The inorg. granular substances are adhered with the curable resin and the numerious fine open cells are formed on the surface part exclusive of the smooth stone material part.

Description

DETAILED DESCRIPTION OF THE INVENTION (Industrial Application Field) The present invention relates to a method for producing a decorated porous material suitable for use as flooring or walling materials.

(Prior Art) Decorated materials such as artificial stone are used as flooring and wall materials. This type of artificial stone is generally made by mixing inorganic powder such as stone with a hardening resin liquid to create a viscous liquid (paste-like) mixture, which is then molded and hardened under normal pressure or pressure. It is manufactured by polishing the surface of this cured product.

However, with this method of polishing the surface of the cured product,
It has the disadvantage that it cannot fully express the luster and texture characteristic of natural stone, and the polishing process increases costs.

In order to improve such drawbacks, for example,
No. 30922 proposes a method of treating the surface of a cured product by wiping it with a curable resin solvent or by immersing it in a solvent. Also, in Japanese Patent Application Laid-Open No. 62-27363,
A method has been proposed in which a mixture of white inorganic fine powder and mica fine pieces is used as a non-powder material such as stone.

(Problem to be solved by the invention) However, even with such improved conventional methods,
Improvements in the luster and texture peculiar to natural stone are not sufficient.

Moreover, according to the former improvement method, since the resin on the surface is dissolved with a solvent, relatively large depressions are created around the inorganic powder such as stone on the surface of the resulting artificial stone.
There is a problem in that dirt tends to adhere to this recess. According to the latter improvement method, mica fine particles are dispersed throughout and arranged irregularly, so a large amount of mica fine particles are required, and the surface of the resulting artificial stone is substantially smooth, making it difficult to slip, especially when wet with water. The problem is that it is easy.

The present invention solves these problems with conventional methods, and its purpose is to create a decorative stone that has the excellent luster and texture characteristic of natural stone, is resistant to stains, and is non-slip even when wet. An object of the present invention is to provide a method for manufacturing a porous material.

(Means for Solving the Problems) The method for producing a decorated porous material of the present invention is to place flaky or scale-like stone coated with a curable resin liquid on the surface of a mold, and then The method is characterized in that inorganic powder particles mixed with a curable resin liquid and made into a wet state are spread and then pressure-molded, thereby achieving the above object.

In the present invention, flaky or scaly stone materials include:
Natural stones such as granite and serpentine sliced into flakes, and flakes such as mica, masconobate, and phlogovite (preferably flat so that they can be placed stably on the mold surface, and the flat surface is generally rectangular) (Although triangular shaped stones are often used, it is not limited to this, and there may be a partially thick walled part.) Stone materials are used. These stones preferably have a size of about 5 to 20 mm. Then, such flaky or scale-like stones coated with a curable resin are used.

In addition, examples of inorganic powders include quartz, kaolin, clay,
Inorganic powder and granules such as silica sand and crushed natural stone powder, natural mineral fibers,
Powders of inorganic short fibers such as glass milled fibers, alumina short fibers, potassium titanate short fibers, carbon short fibers, and voice car are used. The maximum particle size of inorganic powder is
The amount is preferably 1000 μl or less. When the maximum particle size exceeds 1000 μm, the pores formed on the surface of the resulting porous material become large, and dirt and the like easily enter the pores and become dirty.

In addition, as the curable resin, unsaturated polyester resin,
Room-temperature-curing or thermosetting resins are used, such as diallyl phthalate resins, epoxy resins, phenolic resins, and acrylic resins, combined with conventional curing agents and catalysts such as organic peroxides, amines, and acid anhydrides. A curing accelerator is added according to the conditions. The curable resin is used in liquid form, and its viscosity is preferably adjusted to 100 poise or less at room temperature using a solvent or the like. If the viscosity is higher than 100 voids at room temperature, secondary aggregation is likely to occur when coating flaky or scaly stone or when mixing with inorganic powder.

To coat flaky or scaly stone with a hardening resin liquid, the stone is immersed in the hardening resin liquid, or the stone is sprayed with the hardening resin liquid, and the hardening resin liquid is applied to the surface of the stone. Known coating methods such as uniform deposition methods are employed.

Although it is not necessary that the entire surface of the stone is coated with the curable resin liquid, it is preferable that the curable resin liquid adheres to 50% or more of the surface.

When mixing the curable resin liquid with the inorganic powder, the mixing amount is such that the inorganic powder is moistened with the curable resin and maintains the powder state. It is determined by considering the type, particle size, type and viscosity of the curable resin liquid, etc. Generally, 65 to 85% by weight of inorganic powder and curable resin W1.
It is prepared in a range of 35-15% by weight. At this time, various desired pigments may be mixed. In this way, the inorganic powder is mixed with the curable resin liquid and made into a wet state.

In the present invention, first, flaky or scaly stone coated with a curable resin liquid is placed on the surface of a mold by an appropriate method such as manual work. In this case, the stones are placed flat with gaps between them.Next, inorganic powder and granules mixed with the curable resin liquid and made wet are spread over the entire surface, and then, for example, at room temperature. Temperature of ~120°C, 1~
Pressure molding is performed using a press machine or the like at a pressure of 150 kg/c+fl. In this way, a porous material decorated to look like natural stone is obtained.

(Function) In the method of the present invention, flaky or scaly stone coated with a curable resin liquid is placed on the surface of the mold, and on top of it is inorganic powder mixed with the curable resin liquid and made into a wet state. Since the granules are laid out and then pressure-molded, there is no large unevenness on the surface of the resulting porous material that can accumulate dirt, and the surface portion is coated with a curable resin in the form of flakes or scales. stones are placed flat and securely.

In addition, since the inorganic powder moistened with the above-mentioned curable resin liquid is pressure-molded, the inorganic powder is bound by the curable resin and does not open on surfaces other than smooth stone parts. A porous material having a large number of fine pores is obtained.

(Example) Examples and comparative examples of the present invention are shown below.

↓ Scale-shaped mica (6 to 7 mm in diameter) coated by immersing it in a thermosetting unsaturated polyester resin liquid is placed on a flat mold as appropriate so that there are about 20 pieces per 10 cm + n x 10 cm. They were placed manually with gaps between them. On top of this, 25 parts by weight of a thermosetting unsaturated polyester resin liquid (6 voids) and 75 parts by weight of wollastonite (400 mesh pass) were uniformly mixed, and the inorganic powder and granules moistened with the resin liquid were added. The resin was spread uniformly and press-molded at a temperature of 100° C. and a pressure of 100 kg/CIIT to cure the resin, thereby producing a decorated porous material with a thickness of 4 ann.

This porous material has beautiful appearance, stain resistance,
The slip resistance, pore diameter, and pore volume were measured and evaluated using the following methods. The results are shown in Table 1.

(1) For the beauty of appearance, the degree of gloss and texture unique to natural stone was determined by visual inspection, and excellent cases were expressed as ◎, good cases as ○, and poor cases as ×.

(2) Stain resistance is determined by talc powder (particle size of 10 μm or less)
is dispersed in water at a rate of 0.2 g/cc, and 50 cc of this dispersion is sprinkled on the surface of a 100 mm x 100 mm porous material, and the case where the talc powder remains on the surface and can be washed off later is ◎ , The case where the talc powder caused clogging in the pores on the surface was indicated by ×.

(3) Slip resistance was determined by layering a 30mm x 50mm piece of synthetic leather on the surface of the porous material in a wet state, and applying 2K to this.
Place a load of 100 g on it and measure the friction coefficient by the slope method. If the friction coefficient is 0.8 or more, ◎, if it is less than 0.8 to 0.6, ○, or 0.
．． Values less than 6 are indicated by ×.

(4) The diameter of the pores is measured using a mercury porosimeter, and ◎ indicates that less than 10% of pores have a pore diameter of 1 μm or more, and 1
10% or more pores with μI or more and 1 pore with a pore diameter of 5 μm or more
A case where the percentage of pores was less than 0% was indicated by ◯, and a case where the number of pores having a pore diameter of 5 μm or more was 10% or more was indicated by ×.

(5) The pore volume is measured with a mercury porosimeter, and ◎ is 0.1 cc/g or more, and ◎ is less than 0.1 to 0.05 cc.
/g is represented by ◯, and less than 0.05 cc/g is represented by ×.

Fugai Nanayu flaky granite (diameter: approximately 20rIIfnΦ), which has been previously immersed in a thermosetting epoxy resin solution and coated, is placed on a flat mold by hand, leaving appropriate gaps so that there are approximately 10 pieces per 10an x 10ci. Placed at work. On top of this, 27 parts by weight of thermosetting epoxy resin liquid (12 poise) and mineral fiber (
Franklin Huaihani USA [1, S GYPSUM
Y-type 50M00) y'/Yupas) was mixed uniformly with 73 parts by weight, and the powder and granules moistened with the resin liquid were spread uniformly, and this was heated at a temperature of 80 °C and 80 kg.
The resin was cured by press molding at a pressure of /cd to produce a decorated porous material with a thickness of 4 mm.

The surface condition, stain resistance, slip resistance, pore diameter, and pore volume of this porous material were measured and evaluated in the same manner as in Example 1. The results are shown in Table 1.

Point base 1 Thin flaky serpentine stones (diameter: approximately 10 mmΦ) that have been soaked and coated in a thermosetting acrylic resin liquid are placed on a flat mold at appropriate intervals so that there are approximately 20 pieces per 10 cm x 10 cm. Placed by hand. On top of this, 20 parts by weight of thermosetting acrylic resin syrup and attapulgite (40 parts by weight)
0 mesh bath) and 80 overlapping parts were uniformly mixed, the powder and granules moistened with the resin syrup were evenly spread, and this was press-molded at a temperature of 80°C and a pressure of 100 kg/afl. The resin was cured to produce a decorated porous material with a thickness of 4 cylinders.

The surface condition, stain resistance, slip resistance, pore diameter, and pore volume of this porous material were measured and evaluated in the same manner as in Example 1. The results are shown in Table 1.

According to the method described in Comparative Flaming Special Publication No. 50-30922, 18 parts by weight of a cold-curing unsaturated polyester resin liquid (6 poise) and 82 parts by weight of akansuite (50 to 150 mesh) were uniformly mixed to form a paste. made things. This paste-like material is poured into a flat mold and cured at room temperature, and when the surface hardness of the cured product reaches 30 on the Bacall hardness tester, it is removed from the mold and cooled.
This was immersed in acetone to produce an artificial stone with a thickness of about 4 mm.

Regarding this artificial stone, the surface condition, stain resistance, slip resistance, pore diameter, and pore volume were measured and evaluated in the same manner as in Example 1. The results are shown in Table 1.

30 parts by weight of thermosetting acrylic resin syrup, 65 parts by weight of fine calcium silicate powder (average particle size 10 μm) and fine muscovite pieces (with a diameter of about 0 μm) were prepared by the method described in JP-A No. 62-27363. .2 Peng Φ) were mixed uniformly to make a paste. Pour this paste into a flat mold.8
It was cured at 0°C to produce an artificial marble with a thickness of about 4 mm.

This artificial marble has a beautiful appearance, stain resistance,
The slip resistance, pore diameter, and pore volume were measured and evaluated in the same manner as in Example 1. The results are shown in Table 1.

(See the margin below) Table 1 Therefore, the decorated porous material obtained by the method of the present invention can be used on floors expected to have a non-slip effect, such as bathrooms, toilets, galleys, entrances, balconies, shower rooms, poolsides, sidewalks, etc. It can be suitably used for wood, counters, tables, moisture absorbing/releasing wall materials, soundproof building materials, etc.

(Effects of the Invention) As described above, according to the manufacturing method of the present invention, there is no occurrence of unevenness on the surface, and the flaky or scale-like stones coated with a hardening resin on the surface are arranged flat and reliably. By using a small amount of stone, it is possible to obtain a porous material decorated to look like natural stone with the deep luster and texture unique to natural stone. A porous material with a large number of pores opened on the surface is obtained, and it is difficult to slip even when wet with water, and is less prone to staining due to clogging.

Claims (1)

[Claims] 1. A flaky or scale-like stone coated with a curable resin liquid is placed on the surface of the mold, and on top of it is spread an inorganic powder that has been mixed with the curable resin liquid and made into a wet state. 1. A method for producing a decorated porous material, the method comprising pressure-molding a decorated porous material.