JPH0585862A - Scagliolia and its production - Google Patents

Abstract

PURPOSE:To readily produce scagliolia having appearance full of variety. CONSTITUTION:A transparent gel coat surface layer 1 having approximately uniform thickness is formed from a synthetic resin on the surface of a mold 10, a ununiformed structure 2 made of a synthetic resin material equal to or similar to the synthetic resin is made on the gel coat surface layer 1 and a resin concrete layer 3 is piled and formed on the ununiform structure to give scagliolia having the ununiform structure 2 between the gel coat surface layer 1 and the resin concrete layer 3. By changing the ununiform structure, scagliolia having different appearance can be simply produced. The appearance of the scagliolia can be partially changed.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a technique relating to artificial marble, which is a material for bathtubs, washstands and the like, and a method for producing the artificial marble, and is capable of easily producing a product having a novel appearance that has never been seen before. The purpose is.

[0002]

2. Description of the Related Art Artificial marble is often used as a material for manufacturing high-quality bathtubs and washstands. Artificial marble has the advantage that it has a high quality that closely resembles natural stone and is cheaper than natural stone.

Conventionally, artificial marble is manufactured as shown in FIG. First, as shown in (A), an uncured transparent synthetic resin material is sprayed onto the molding surface of the molding die 10 using a spray gun 20 or the like to obtain a uniform thickness of about 0.2 to 0.5 mm. A thin gel coat surface layer 1 is formed. After the gel coat surface layer 1 is cured, as shown in (B), a mixture of an uncured synthetic resin material and an inorganic or organic filler is poured onto the gel coat surface layer 1 to cure it. Then, the resin concrete layer 3 having a constant thickness is formed. In this way, the artificial marble having the appearance and the tone of the resin concrete layer 3 on the inside through the transparent gel coat surface layer 1 and having the appearance for natural stone is obtained.

[0004]

As described above, the appearance of the conventional artificial marble is determined by the surface texture of the resin concrete layer 3 inside the gel coat surface layer 1. That is, the appearance of the product is almost determined by the material of the resin concrete layer 3 and the kind of the filler.
For this reason, the conventional artificial marble products are forced to have a uniform outer appearance, and it is difficult to partially change the appearance. Moreover, to change the appearance specifications,
Since the material of the resin concrete layer 3 must be adjusted differently, there is a drawback that it takes a lot of time.

[0005]

The present invention was devised in view of the above-mentioned problems of the prior art, and is characterized in that the molding surface of a molding die is made of a synthetic resin and has a substantially uniform thickness. By forming a non-uniform structure on the gel coat surface layer of the synthetic resin material of the same or similar material as the synthetic resin on the gel coat surface layer, by forming a resin concrete layer on top of these , To obtain an artificial marble having a non-uniform structure formed between the gel coat surface layer and the resin concrete layer. It is optimal that the thickness of the gel coat surface layer is set to about 0.2 to 0.5 mm, and the maximum thickness of the non-uniform structure is set to about 0.5 to 1.0 mm.

[0006]

According to the present invention, the appearance of the obtained artificial marble is due to the surface texture of the resin concrete layer which is visible through the gel coat surface layer and the heterogeneous structure inside thereof. That is, even if the material of the resin concrete layer is the same, the appearance can be changed by changing the non-uniform structure. Therefore, since it is not necessary to modify the resin concrete layer, it is extremely easy to change the appearance specifications.

Moreover, since the non-uniform structure can be partially formed, the appearance can be partially changed.

[0008]

【Example】

(First Embodiment) FIGS. 1A to 1C show a manufacturing procedure of an artificial marble according to a first embodiment of the present invention. This will be described. First, as shown in FIG. 1A, the spray gun 20 is applied onto the molding surface of the molding die 10 in the same manner as in the conventional case.
Etc., a synthetic resin material is sprayed and cured to form the gel coat surface layer 1 having a thin uniform thickness of about 0.2 to 0.3 mm. As the synthetic resin for the gel coat layer 1, a bisphenol-based or isophthalic acid-based unsaturated polyester resin that is transparent after curing is used.

Next, a non-uniform structure 2 as shown in FIG. 1B is formed on the gel coat layer 1 by using a synthetic resin material of the same or similar material. The non-uniform structure 2 in the first embodiment is the uneven layer 2a. The height of the convex portion may be formed to be substantially constant, but is 0.5 to
It may be formed so that the height of the convex portion changes within a range of about 1.0 mm. In addition, the means for forming the uneven layer 2a changes the moving speed of the hopper 30 (or nozzle) for supplying the uncured synthetic resin material, changes the supply speed of the synthetic resin material, or changes these. A method of using them in combination can be mentioned.

It should be noted that the synthetic resin material supplied from the hopper 30 must maintain the uneven shape until the hardening proceeds to some extent. Therefore, the synthetic resin material for the heterogeneous structure 2 is adjusted to increase thixotropy, and the fluidity is kept high in the hopper 30 by stirring and vibration, and the fluid is supplied onto the gel coat surface layer 1 to be static. Immediately after the gel is placed, the gelation proceeds and the shape-retaining property is exhibited. When the thixotropy of the synthetic resin for the gel coat surface layer 1 required to have fluidity for uniform thickness is 3 to 6, the thixotropy of the synthetic resin for the heterogeneous structure 2 is set to 10 to 15.

After the non-uniform structure 2 is formed in this manner, it is superposed on it as shown in FIG. 1C, and the hopper 40 is prepared by mixing the uncured synthetic resin material with the filler by the same means as the conventional one. To a certain thickness to form a resin concrete layer 3. What is generally used as a material for the resin concrete layer 3 is a mixture of an unsaturated polyester resin and a filler such as aluminum hydroxide or calcium carbonate, but the material is not limited thereto. After that, after the resin concrete layer 3 is hardened, it is taken out from the molding die 10 to obtain the target artificial marble.

Since the artificial marble manufactured as described above has the non-uniform structure 2 having a non-uniform thickness between the gel coat surface layer 1 and the resin concrete layer 3,
When viewed from the surface side, the resin concrete layer 3 has an appearance as if the surface properties of the resin concrete layer 3 are changed. In other words, the concave and convex portions of the concave-convex layer 2a cause a difference in depth and shade in the color tone, which gives a complicated and delicate appearance. In addition, in the present invention, since it is easy to change the uneven shape, the uneven shape may be changed depending on the portion, the unevenness may be partially omitted, or conversely, the unevenness may be provided only in a specific region. It is possible to easily realize application examples such as. Moreover, the appearance obtained by the present invention is more uniform than that of natural stone because the entire appearance is not uniform.

(Second Embodiment) The non-uniform structure 2 which is a feature of the present invention can have various modes other than the above. For example, in the embodiment shown in FIGS. 2 and 3, a plurality of nozzles 3 are provided on the gel coat surface layer 1 formed on the molding surface of the molding die 10.
Synthetic resin material is supplied from 0 at the same time, and parallel ridges 2b
Is formed. Therefore, in this embodiment, the parallel stripe pattern appears in the appearance due to the nonuniform structure 2 including the parallel protrusions 2b.

(Third Embodiment) When the non-uniform structure 2 is composed of a plurality of ridges as in the above embodiment, not only each ridge is formed in a straight line, but also as shown in FIG. , May be formed so as to draw a wavy curve. Furthermore, it is possible to prevent the surface pattern from becoming monotonous by mixing the small protrusions 2b-1 and the large protrusions 2b-2. In the third embodiment, the non-uniform structure 2 is thus formed into a plurality of protrusions 2b-which are curved in a wave shape and have different width dimensions.
Since it is 1 and 2b-2, an extremely natural flow pattern is expressed.

(Fourth Embodiment) The non-uniform structure 2 formed on the gel coat surface layer 1 does not necessarily have to be continuous, and as shown in FIGS. 5 and 6, a hopper 31 having a plurality of openings 32. It is also possible to form a structure in which a large number of point-shaped projections 2c are scattered by continuously or intermittently dropping an uncured synthetic resin material having a high degree of rocking while moving. The arrangement of the dot-shaped convex portions 2c may be regular or irregular, and is appropriately selected as desired. Due to the non-uniform structure 2 composed of the above point-shaped convex portions 2c,
The artificial marble according to the fourth embodiment has a speckled pattern.

(Fifth Embodiment) FIG. 7 shows an embodiment in which a second gel coat layer 2d whose thickness continuously or stepwise changes is formed on the gel coat surface layer 1. Therefore, the artificial marble manufactured based on this example,
The product gives an appearance in which the color tone changes continuously or stepwise.

(Other Examples) In each of the above examples, the color tone may be made uniform between the gel coat surface layer 1 and the non-uniform structure 2 formed thereon, but the color tone may be different. I can. By changing the color tone, a change in color appears as well as the shade of the hue, so that a more complicated appearance can be provided, and monotonicity when observed as a whole can be avoided. Further, by using some of the aspects of the non-uniform structure 2 described in each of the above-mentioned embodiments, it is possible to develop the present invention such as imparting more various appearances. As described above, the present invention does not prevent various changes, and can select the optimum mode according to the implementation situation.

[0018]

According to the present invention, in the artificial marble,
Since the non-uniform structure is formed between the gel coat surface layer and the resin concrete layer, various appearances can be easily obtained by variously changing the mode of the non-uniform structure. Moreover, since the formation of the non-uniform structure and the change of the mode are extremely simple, compared with the conventional case where the adjustment of the resin concrete layer is modified, the production of many kinds of artificial marble is much simplified. realizable.

In addition, since the non-uniform structure according to the present invention can be partially provided, it is possible to easily obtain a product whose appearance is partially changed and which is extremely difficult to manufacture by the conventional technique. Is.

[Brief description of drawings]

FIG. 1 is a longitudinal sectional view showing a procedure for producing an artificial marble according to a first embodiment of the present invention, in which (A) shows a state in which a gel coat surface layer is formed on a molding surface of a molding die; () Is a vertical cross-sectional view showing a situation in which a non-uniform structure composed of a concavo-convex layer is formed on a gel coat surface layer, and (C) is a vertical cross-sectional view showing a situation in which a resin concrete layer is further stacked.

FIG. 2 is a vertical cross-sectional view showing a second embodiment of the present invention and showing a procedure for forming a plurality of parallel ridges on a gel coat surface layer.

FIG. 3 shows a second embodiment of the present invention and is a perspective view showing a state in which a non-uniform structure composed of a plurality of parallel ridges is formed on a gel coat surface layer.

FIG. 4 shows a third embodiment of the present invention and is a perspective view showing a state in which a non-uniform structure composed of a plurality of wavy curved ridges is formed on a gel coat surface layer.

FIG. 5 is a vertical cross-sectional view showing a fourth embodiment of the present invention and showing how to form a large number of dot-shaped convex portions on the gel coat surface layer.

FIG. 6 is a perspective view showing a fourth embodiment of the present invention and showing a state in which a non-uniform structure composed of a large number of point-like convex portions is formed on a gel coat surface layer.

FIG. 7 is a perspective view showing a fifth embodiment of the present invention, showing a state in which a non-uniform structure composed of a second gel coat layer having a continuously changing thickness is formed on a gel coat surface layer. Is.

FIG. 8 shows a conventional procedure for producing artificial marble, where (A) is a vertical sectional view showing a state in which a gel coat surface layer is formed on the molding surface of a molding die, and (B) is a top view of the gel coat surface layer. FIG. 6 is a vertical cross-sectional view showing a situation in which a resin concrete layer is formed on the substrate.

[Explanation of symbols]

 1 ... Gel coat surface layer 2 ... Non-uniform structure 3 ... Resin concrete layer 10 ... Mold

─────────────────────────────────────────────────── ─── Continuation of the front page (51) Int.Cl. ⁵ Identification code Office reference number FI technical display location B32B 33/00 7141-4F C04B 26/18 6345-4G

Claims (2)

[Claims] 1. Between the transparent gel coat surface layer formed of a synthetic resin and having a substantially uniform thickness, and the resin concrete layer formed on the back side of the gel coat surface layer, the same or similar quality as the synthetic resin. An artificial marble characterized by having a non-uniform structure formed of synthetic resin material. 2. A transparent gel coat surface layer having a substantially uniform thickness is formed on the molding surface of a molding die by a synthetic resin, and the gel coat surface layer is non-uniform due to a synthetic resin material of the same or similar material as the synthetic resin. A method for producing an artificial marble, which comprises forming a structure and then forming a resin concrete layer on top of them to form a structure.