JPH06293550A - Artificial stone and production therefor - Google Patents

Abstract

PURPOSE:To produce an artificial stone of high productivity which provides sufficient strength and heat resistance and also is excellent in the appearance. CONSTITUTION:A mold-releasing sheet 2 is laid on an Al plate 1a and a spacer 3 is provided at the three sides of the upper surface peripheral part by surrounding it and a first composition 4 consisting of 1% methacrylic resin, 4% polyester resin, 27% sodium silicate, 67% alumina powder and 1% iron oxide power is flowed on the mold-released sheet 2 to figure a pattern. Plural sheets of such the Al plates are laminated and a mold is composed and after the first composition 4 was allowed to gelatinize by being left standing for 25 minutes, the mold frame is stood up and a second composition consisting of 0.6% methacrylic resin, 4% polyester resin, 20% sodium silicate, 30% powdery alumina, 0.4% powdery iron oxide, and 45% white marble rubbles is poured in the mold frame to cure by heating at 80 deg.C for 2.5 hours.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an artificial stone used for interior and exterior of buildings, materials for crafts, etc., and a method for producing the same.

[0002]

2. Description of the Related Art As this type of artificial stone, so-called artificial marble is generally popular. Conventional artificial marble is roughly classified into one mainly composed of cement and one mainly composed of synthetic resin. The former is generally manufactured by pouring white cement into the mold to form a surface layer and lining the reinforcing layer from the back side with mortar. In some cases, various agents and pigments were mixed. The latter is generally produced by using particles of marble, cold water stone, aluminum hydroxide, calcium carbonate, etc. as a filler, polyester resin, epoxy resin, acrylic resin, etc. as a binder, kneading them, and then molding. Met.

[0003]

The conventional artificial marble using cement requires about 5 to 7 days to be hardened and cured, and its productivity is extremely low. there were. In addition, since the material is fragile, processing such as cutting is difficult, and in order to obtain sufficient strength, the product thickness must be about 15 mm or more, which is heavy and hinders transportation and handling. There was also a drawback. Further, in the conventional artificial marble using a synthetic resin, in order to obtain sufficient strength, it is necessary to increase the resin compounding ratio to about 30 to 60% by weight of the whole, so that the heat resistant temperature is 180 ° C.
It had the drawback of being low.

In view of the above-mentioned drawbacks of the prior art, the present invention provides an artificial stone having high productivity, sufficient strength and heat resistance, and excellent appearance, and a method for producing the artificial stone. Has an aim.

[0005]

In order to achieve the above object, an artificial stone according to the invention of claim 1 contains a methacrylic resin, a polyester resin, sodium silicate, and an alumina powder. It is characterized in that the composition is cured.

In the method for manufacturing an artificial stone according to the second aspect of the present invention, a composition containing a methacrylic resin, a polyester resin, sodium silicate, and alumina powder is poured into a mold. It is characterized by being cured.

In the method for manufacturing an artificial stone according to the third aspect of the present invention, the first composition containing a methacrylic resin, a polyester resin, sodium silicate, and alumina powder is used as a mold. After being applied to at least a part of the inner wall surface of and gelled, a second acrylic resin containing a methacrylic resin, a polyester resin, sodium silicate, and alumina powder and having a different color tone from the first composition The composition is poured into the mold to be cured.

Further, in the method for manufacturing an artificial stone according to the invention described in claim 4, a cloth or paper impregnated with a mixture of a methacrylic resin and a polyester resin is attached to at least a part of the inner wall surface of the mold. The method is characterized in that, after gelling the mixture, a composition containing a methacrylic resin, a polyester resin, sodium silicate, and alumina powder is poured into the mold and cured. is there.

Further, in the method for manufacturing an artificial stone according to the invention of claim 5, a urethane resin is applied to the surface of a wood sheet and cured, and then a methacrylic resin and a polyester resin are applied on the urethane resin. And a mixture of the wood sheet and at least a part of the inner wall surface of the mold, after gelling the mixture, a methacrylic resin, a polyester resin, sodium silicate, and alumina powder. Pour the composition containing into the mold,
It is characterized by being cured.

[0010]

In the artificial stone according to the first aspect of the present invention, synthetic resin (methacrylic resin and polyester resin) and sodium silicate are used as the binder, and alumina powder or the like is used as the filler.

By blending the binder with sodium silicate having a high heat-resistant temperature, the blending ratio of the synthetic resin having a low heat-resistant temperature can be significantly reduced as compared with the artificial marble using the conventional synthetic resin. The heat resistance of the stone is improved.

The methacrylic resin blended as a synthetic resin in the binder has the advantages of high transparency and excellent weather resistance, but has the drawback of shrinking during curing. Also,
The polyester resin has an advantage that the shrinkage upon curing is small, but has a drawback that it has low transparency and poor weather resistance. However, by blending both of these resins, the drawbacks can be eliminated and the advantages can be exhibited.

Alumina powder mixed as a filler is mixed with a binder to obtain strength, acid resistance and
The properties such as alkali resistance and heat resistance are remarkably improved. In the present invention, even if the compounding ratio of the synthetic resin is reduced, the insufficient strength of the artificial stone can be compensated by the compounding of the alumina powder. Further, since alumina powder has a small refractive index and becomes transparent when mixed with a resin, an artificial stone having a transparent feeling can be obtained by blending it. It should be noted that fillers other than alumina powder can be blended.

In the method for producing an artificial stone according to the second aspect of the invention, the uncured composition obtained by kneading the filler and the binder as described above is poured into a mold to be cured, and then the mold is molded. An artificial stone is obtained by separating it from the frame. The type and amount of the curing accelerator and the curing conditions are arbitrary. In addition, when coloring artificial stones, a pigment is added to the composition, but the type and amount are also arbitrary.

In the method for producing an artificial stone according to the third aspect of the present invention, the first composition is applied to the inner wall surface of the mold to draw a pattern, which is gelled, and then the first composition is gelled. A second composition having a color tone different from that of the composition, that is, having a different composition ratio of the first composition and the pigment, or a pigment having a different color from the first composition is poured into the mold. . As a result, the first composition is slightly melted by the second composition and is flowed, so that the boundary between the first composition and the second composition appearing in the surface layer portion of the artificial stone after hardening is blurred. As a result, artificial stones with a natural marble-like pattern are obtained.

If the second composition is poured before the first composition gels, the entire first composition will be poured and the pattern will disappear, and the first composition will also disappear. When it is poured into the artificial stone after it has hardened almost completely, the first composition does not flow at all, so the boundary between the first composition and the second composition that appears on the surface layer of the artificial stone after hardening becomes clear. It doesn't look natural.

In the method for manufacturing an artificial stone according to the fourth aspect of the present invention, a cloth or paper impregnated with a mixture of synthetic resins (methacrylic resin and polyester resin) is attached to the inner wall surface of the mold to form the mixture. After gelling, the composition is poured into a mold. As a result, the mixture and the composition are combined, and the cloth or paper is integrated and cured with the surface of the cloth or paper protected by the transparent synthetic resin layer, so that the pattern of the cloth or paper forms the synthetic resin layer. An artificial stone that penetrates and appears on the surface layer can be obtained.

If the composition is poured before the mixture gels, the cloth or paper may float from the inner wall surface of the mold, and if the composition is completely cured and then poured, the composition of the mixture and the composition may be increased. It may not bond well with the object and may peel off at the interface.

In the method for producing an artificial stone according to the present invention as defined in claim 5, a urethane resin is applied on the surface to be cured, and then a mixture of synthetic resins (methacrylic resin and polyester resin) is applied on the wood. The sheet is attached to the inner wall surface of the mold, the mixture is gelated, and then the composition is poured into the mold. As a result, the mixture and the composition are combined, and the wood sheet is integrated and cured with the surface of the wood sheet protected by the transparent synthetic resin layer, so that the wood pattern penetrates the synthetic resin layer. The artificial stone that appeared in the surface layer can be obtained.

It should be noted that the urethane resin is first applied to the wood sheet, because if the mixture of the methacrylic resin and the polyester resin is applied directly to the wood sheet, color unevenness may occur due to uneven penetration of the resin into the wood. The reason is that the resin will be prevented from being hardened by the resin of the wood.

[0021]

Embodiments of the present invention will be described below with reference to the drawings. All% in the examples mean% by weight. Example 1. A release sheet 2 made of Teflon (trademark of DuPont) having a smooth surface was laid on a square aluminum plate 1a having a square shape of 1.1 m, and a diameter of 7 mm was provided on three sides of the peripheral edge of the upper surface.
A spacer 3 made of silicone rubber in the shape of a round bar is provided around the first composition consisting of 1% methacrylic resin, 4% polyester resin, 27% sodium silicate, 67% alumina powder, and 1% iron oxide powder (pigment). The kneaded product 4 was thinly and partially cast on the release sheet 2 to draw a pattern (see FIG. 1). Then, another aluminum plate 1b was placed on the spacer 3, the release sheet 2 was laid on the aluminum plate 1b in the same manner, and a pattern was drawn by the first composition 4. In this way, the five aluminum plates 1a to 1e are stacked while drawing a pattern, and finally the other aluminum plate 1f is placed, so that these aluminum plates 1a to 1f are not separated. The mold 5 was configured by clamping the four corners in the thickness direction with clamps (not shown) (see FIG. 2).

In this state, the mixture was allowed to stand for about 25 minutes to gel the first composition 4, and then the mold 5 was erected so that the side where the spacer 3 was not provided faced up. 6%, polyester resin 4%, sodium silicate 20%,
A second composition 6 consisting of 30% of alumina powder, 0.4% of iron oxide powder (pigment), and 45% of crushed cold water stone (natural white marble) was kneaded, and the aluminum plate 1 It was poured in between. Then, this was heated in a heater at 80 ° C. for 2.5 hours to be hardened, then cooled to room temperature, the clamp was removed, and the mold 5 was disassembled. As a result, a square plate-shaped artificial stone 7 having a side length of less than 1 m and a thickness of less than 7 mm was obtained (see FIG. 3).

The surface of the artificial stone 7 which was in contact with the release sheet 2 was a mirror-like surface with transparency, and the pattern of the first composition 4 appeared on this surface. The boundary between No. 4 and the second composition 6 was blurred, and exhibited an extremely natural and high-grade visual sense such as natural marble. Moreover, the texture of the surface and the sound emitted when the artificial stones 7 were mutually abutted were very similar to natural marble. Further, since this artificial stone 7 has sufficient strength and is not brittle, it was easy to cut and engrave it on its surface. Furthermore, about 40 with a gas burner
Although it was heated to 0 ° C, it did not melt or burn and was excellent in weather resistance and chemical resistance. Further, in the present embodiment, the surface of the artificial stone 7 is mirror-like, but if the release sheet 2 has fine irregularities on the surface, the surface of the artificial stone 7 thus produced is made matte. I was able to.

It should be noted that sodium silicate has poor wettability with alumina powder and other fillers, and if it is too much, the blending ratio of the synthetic resin must be reduced and the strength of the artificial stone becomes insufficient. On the other hand, the hardening rate of stone became slow, while when the blending ratio of sodium silicate was too small, it was necessary to increase the blending ratio of synthetic resin, and the heat resistance of the product tended to be lowered. Therefore, preferable results were obtained when the sodium silicate content was in the range of 5 to 30% of the composition.

Synthetic resins (methacrylic resin and polyester resin) have a stronger binding force than sodium silicate, but they are inferior in heat resistance. Therefore, if the compounding ratio is too large, the heat resistance of the artificial stone will be deteriorated. When it passed, the strength of the artificial stone tended to be insufficient. Therefore, preferable results were obtained when the synthetic resin was in the range of 2 to 6% of the composition.

Further, the methacrylic resin in the synthetic resin is 1
If it is less than / 10, the transparency of the artificial stone tends to be insufficient and the sense of quality tends to be poor. On the other hand, if it exceeds 4/10, the surface of the artificial stone has irregularities due to so-called thinning or cracks occur in the artificial stone. There is a high possibility that Therefore, it is preferable that the ratio of the methacrylic resin to the polyester resin in the synthetic resin is about 1: 9 to 4: 6 (weight ratio).

Further, if the compounding ratio of the alumina powder is less than 20% by weight based on the whole amount, the strength and heat resistance of the artificial stone are insufficient and the transparency of the artificial stone tends to be insufficient.

By adding a small amount of condensed phosphate to the composition, the heat resistance of the artificial stone was further improved.

Example 2. As in Example 1, a release sheet having a smooth surface made of Teflon is laid on a quadrangular aluminum plate, and a spacer made of silicon rubber in the shape of a round rod having a diameter of 10 mm is provided around the peripheral edge of the upper surface on three sides. did. Then, a cotton cloth with a pattern was dipped in a mixture of synthetic resins mixed at a weight ratio of methacrylic resin: polyester resin = 8: 2, and this was attached onto the release sheet. In this way, five aluminum plates are stacked while adhering the cloths soaked in the mixture, and finally another aluminum plate is placed, and then the four corners in the thickness direction are clamped with the same clamps as in Example 1. Tightened to form the formwork.

In this state, the mixture was allowed to stand for about 20 minutes to gelate the mixture of synthetic resins, and then a mold was erected, and 0.3% of methacrylic resin, 2.7% of polyester resin and 2 parts of sodium silicate were used.
A kneaded composition of 8%, alumina powder 29%, and natural marble crushed stone 40% was poured into a mold. Then, this was cured in a heater at 80 ° C., cooled to room temperature, the clamp was removed, and the mold was disassembled. As a result, a square plate-shaped artificial stone 8 having a side length of less than 1 m and a thickness of less than 10 mm was obtained.

The artificial stone 8 is formed by firmly bonding the thin synthetic resin layer 9 on the side in contact with the release sheet and the thick composition layer 10, and the synthetic resin layer 9 protects the cloth 11. The texture of the pattern and its fabric penetrated the transparent synthetic resin layer 9 and appeared on the surface, resulting in a high-quality artificial stone (see FIG. 4). Note that paper can be used instead of the cloth 11.

Example 3. Urethane resin was applied to both surfaces of a wood sheet made of cypress wood sliced to a thickness of 3 mm, and dried and cured. Then, as in Example 1, a release sheet having a smooth surface made of Teflon is laid on a rectangular aluminum plate, and a spacer made of silicon rubber in the shape of a round rod having a diameter of 10 mm is provided on three sides of the upper surface peripheral edge. It was set around. Then, the wood sheet coated with the urethane resin was dipped in a mixture of synthetic resins mixed at a weight ratio of methacrylic resin: polyester resin = 8: 2, and this was attached onto the release sheet. In this way, five aluminum plates are stacked while sticking the wood sheets, and finally another aluminum plate is placed, and then the four corners are clamped in the thickness direction with the same clamps as in the first embodiment. The frame was constructed.

In this state, the mixture was left to stand for about 20 minutes to gel the mixture of synthetic resins, and then the mold was erected, and the methacrylic resin 2%, polyester resin 4%, sodium silicate 10%, alumina powder 24%, natural. The kneaded composition of 60% marble crushed stone was poured into the mold. Then, this was cured in a heater at 80 ° C., cooled to room temperature, the clamp was removed, and the mold was disassembled. As a result, a square plate-shaped artificial stone 12 having a side length of less than 1 m and a thickness of less than 10 mm was obtained.

In this artificial stone 12, the synthetic resin layer 13 on the side in contact with the release sheet and the composition layer 14 are firmly bonded, and the wood grain of the wood sheet 15 protected by the synthetic resin layer 13 The pattern penetrated the transparent synthetic resin layer 13 and appeared on the surface, resulting in a high-quality artificial stone (see FIG. 5). In this artificial stone 12, since the urethane resin has penetrated into the wood sheet 15 and is integrated and cured with the mixture of the methacrylic resin and the polyester resin, the water resistance is high,
Even after soaking in water for several days, the wood sheet 15 was not discolored or peeled off.

[0035]

The artificial stone according to the invention of claim 1 is
By blending sodium silicate with a high heat resistance temperature, the blending ratio of synthetic resin with a low heat resistance temperature can be made lower than that of conventional artificial marble, and alumina powder that improves the strength and heat resistance of the binder can be used. Since it is mixed as a filler, it has the advantages of excellent heat resistance and strength. Further, by blending a methacrylic resin having a high transparency and an alumina powder having a low refractive index of light, there is an advantage that the surface layer portion has a high transparency and is excellent in appearance.

In the method for producing an artificial stone according to the second aspect of the present invention, the above-mentioned artificial stone can be produced with high productivity.

In the method for producing an artificial stone according to the third aspect of the present invention, it is possible to produce a high-quality artificial stone having a natural pattern such as natural marble on the surface layer.

In the method for manufacturing an artificial stone according to the fourth aspect of the present invention, it is possible to manufacture a high-quality artificial stone in which the pattern of cloth or paper has penetrated the synthetic resin layer and appeared in the surface layer portion. it can.

In the method for manufacturing an artificial stone according to the fifth aspect of the present invention, it is possible to manufacture a high-quality artificial stone in which the wood grain pattern appears in the surface layer portion through the synthetic resin layer. .

[Brief description of drawings]

FIG. 1 is a perspective view illustrating a state in which a pattern is drawn with a first composition in Example 1.

FIG. 2 is a perspective view illustrating a mold according to the first exemplary embodiment.

FIG. 3 is a perspective view showing an artificial stone in Example 1.

FIG. 4 is an enlarged perspective view of essential parts showing an artificial stone according to a second embodiment.

FIG. 5 is an enlarged perspective view of essential parts showing an artificial stone according to a third embodiment.

[Explanation of symbols]

 4 First composition 5 Formwork 6 Second composition 7,8,12 Artificial stone 10,14 Composition 11 Cloth 15 Wood sheet

Claims (5)

[Claims] 1. An artificial stone characterized by being obtained by curing a composition containing a methacrylic resin, a polyester resin, sodium silicate and alumina powder. 2. A method for producing an artificial stone, which comprises pouring a composition containing a methacrylic resin, a polyester resin, sodium silicate, and alumina powder into a mold to cure the composition. 3. A first composition containing a methacrylic resin, a polyester resin, sodium silicate, and an alumina powder is applied to at least a part of the inner wall surface of the mold to form a gel. , A methacrylic resin, a polyester resin, sodium silicate, and alumina powder, and a second composition having a color tone different from that of the first composition is poured into the mold and cured. And a method of manufacturing an artificial stone. 4. A cloth or paper impregnated with a mixture of a methacrylic resin and a polyester resin is attached to at least a part of the inner wall surface of the mold to gelate the mixture,
A method for manufacturing an artificial stone, which comprises pouring a composition containing a methacrylic resin, a polyester resin, sodium silicate, and alumina powder into the mold to cure the composition. 5. A urethane resin is applied to the surface of a wood sheet and cured, and then a mixture of a methacrylic resin and a polyester resin is applied onto the urethane resin, and the wood sheet is applied to the inner wall surface of the mold. Attach to at least a part,
After gelling the mixture, with a methacrylic resin,
A method for producing an artificial stone, which comprises pouring a composition containing a polyester resin, sodium silicate, and alumina powder into the mold to cure the composition.