JPH0673946B2 - Artificial marble and manufacturing method thereof - Google Patents

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an artificial marble and a method for producing the same.

[0002]

2. Description of the Related Art Conventionally, artificial marble obtained by mixing an unsaturated polyester resin which constitutes an intermediate layer and the like with an inorganic material and hardening the mixture to form an inorganic material has been widely used. This artificial marble has a profound feeling, and can express various tastes and textures by arbitrarily selecting the type of inorganic material to be mixed. Conventionally, unsaturated polyester resin in which mica is scattered (Japanese Patent Application No. 61-25541), stones such as granite (Japanese Unexamined Patent Publication No. 62-197457), and vinylon Those in which fibers are scattered (Japanese Patent Application Laid-Open No. 57-123
No. 859), and various artificial marbles in which scale-like glass flakes are scattered (JP-A-2-153966).

[0003]

Artificial marble exhibiting brilliance contains mica and scaly glass flakes as described above, but the reflected color is dispersed by the reflected light and the transmitted color. The mica has an interference function of coloring like soap bubbles by interference, and the scale-like glass flakes have a function very similar to the interference function, thereby expressing a glittering color tone. However, in the above-mentioned conventional technology, since the reflection / transmission of light of only the mixed inorganic material (mica, glass flakes, etc.) is used, there is a natural limitation on the light brightness (vividness) and depth, There is a problem in appearance that the high-class feeling and solid feeling are not satisfied.

The present invention has been made in view of such conventional circumstances, and an object thereof is an opal tone which is brighter and deeper than a conventional artificial marble, and is of a higher grade and has a profound feeling. It is intended to provide a novel artificial marble that brings out the color tone of and a manufacturing method thereof.

[0005]

Means for Solving the Problems As a result of intensive studies on the intermediate layer and the mixed material mixed in the intermediate layer, the inventors of the present invention have found that a mixed material that reflects and transmits light in cooperation with the intermediate layer. ,
The inventors of the present invention have found that a material in which an intermediate layer is mixed with a mixed material exhibiting an iris color by the reflected light / transmitted light is optimal for developing an opal tone, and the present invention has been accomplished. That is, the present invention is an artificial marble comprising a transparent surface layer, an intermediate layer made of resin concrete, and a back layer made of FRP,
The intermediate layer is a mixture of a translucent amorphous amorphous material having a crack and a bent and deformed flake-like material having an iris color exposing thin film layer on the surface thereof, and a fine sealing crack having an amorphous particle The gist is that it is a transparent or semi-transparent layer that is present at the boundary with the non-material, and as its manufacturing method, a transparent surface layer, an intermediate layer made of resin concrete, and F
A manufacturing method for manufacturing an artificial marble having a three-layer structure of a back layer made of RP by a casting method, wherein a transparent surface layer is layered on the surface of a molding die, and an intermediate layer made of resin concrete is an unsaturated polyester. Mixing a desired amount of translucent irregularly shaped granular inorganic material that has cracks in the resin component with a curing agent, bent flakes that have an iris color exposure thin film layer on the surface, and a small amount of glass fiber A transparent or semi-transparent molding material prepared by the method described above and having a viscosity of 500 to 1000 poise at 25 degrees Celsius is cast into a molding die, and the molding material is heated to a temperature of 60 degrees Celsius or higher. It is heated and cured so that
The summary is that the back layer made of RP is layered on the molding die in advance or is layered on the molded body after the heat curing. Incidentally, the molding material for the intermediate layer requires a viscosity of 500 to 1000 poise at 25 degrees Celsius. Outside of this range, translucent irregularly shaped granular inorganic materials and flaky materials that are bent and deformed by applying an iris color exposure thin film layer on the surface,
When a shaped object such as a bathtub other than a flat plate is deformed, it flows and cannot be uniformly distributed over the entire middle layer. In addition, a small amount of glass fiber is required to prevent settling of the translucent irregularly shaped granular inorganic material and the flake-like material and to make the volume per unit volume uniform. Further, the molding heat generation temperature needs to be 60 degrees Celsius or higher. If the temperature is not higher than 60 degrees Celsius, a sealing crack cannot be formed at the boundary with the granular inorganic material by utilizing the difference in coefficient of thermal expansion between the translucent amorphous inorganic material and the unsaturated polyester resin during cooling.

[0006]

According to the above technical means, the following actions are achieved. (Claim 1) Diffuse reflection of light from a translucent irregularly shaped granular inorganic material mixed with an intermediate layer and having fine crack-like cracks.
The transmission and diffuse reflection / transmission of the light from the sealing cracks at the boundary with the irregular-shaped inorganic material multiple-reflects the light in random directions as it goes deeper in the intermediate layer, creating a glittering brightness and depth. While expressing, each of the bending-deformable flakes having the iris color exposing thin film layer on the surface develops various rainbow colors depending on the incident angle of incident light. (Claim 2) The viscosity is 500 to 1000 at 25 degrees Celsius.
The intermediate layer, which is made of poise and contains a small amount of glass fiber and a translucent irregular-shaped inorganic material having cracks and a bent and deformed flake-like material for applying the iris color exposure thin film layer, is made of a translucent material. It is layered on the transparent surface layer in a state where the irregular-shaped inorganic material and its bent and deformed flakes do not settle and flow and the bulk density per unit volume is constant. By setting the molding exothermic temperature to 60 degrees Celsius or more, the unsaturated polyester resin at the time of cooling shrinks more than 5 times more than the translucent irregular-shaped granular inorganic material, and the translucent irregular-shaped granular inorganic material. An intermediate layer that naturally forms a sealing crack at the boundary between the transparent layer and the transparent surface layer.

[0007]

Since the present invention is constructed as described above, it has the following advantages. (Claim 1) Random diffuse reflection / transmission of light from a translucent amorphous amorphous inorganic material having cracks and random reflection of light from a sealed crack formed at a boundary between the transparent inorganic amorphous inorganic material and a granular inorganic material. Since transmission and transmission are repeated multiple times as they go deeper in the intermediate layer, and due to the change in the incident angle of light, the flakes individually develop an iris color with different shades,
It is possible to newly provide artificial marble in which the depth and glitter and the iris are expressed in synchronism, and a gorgeous high-class feeling similar to the opal tone of natural stone and a prominent and novel glittering appearance are expressed. (Claim 2) Not to mention the artificial marble of claim 1,
Even irregularly shaped artificial marble such as bathtubs other than flat plates can be translucent, such as irregularly shaped granular inorganic materials or bent flakes that have an iris color exposure thin film layer on the surface, such as sedimentation, deviation, deformation, etc. It is possible to manufacture reliably and with high accuracy without inviting the cause of deterioration of retention.

[0008]

Embodiments of the present invention will now be described with reference to the drawings. In this embodiment, claim 2 and claim 1 are described.

The artificial marble A comprises a transparent surface layer 1 as shown in FIG. 1, an intermediate layer 2 in which a translucent irregularly shaped granular inorganic material 2a and a transparent flake-like material 2b are mixed, and a back layer 3 made of FRP. It is composed of three layers.

The transparent surface layer 1 is a transparent unsaturated polyester resin to which a predetermined curing agent, accelerator, etc. are added.
0.3 to 0.5 on the molding surface b1 'of the male mold b1 of the mold B
It is applied in a thickness of about mm to form a layer (FIG. 3).

The intermediate layer 2 is a translucent amorphous amorphous inorganic material 2a having cracks 2a ', a bent flake-like material 2b in which a transparent plastic film is provided with an iris color exposing thin film layer, and a small amount of glass. Transparent or semi-transparent with a mixture of fibers 2c and fine sealing cracks 2d at the boundary with the translucent irregularly shaped granular inorganic material 2a, and a viscosity of 800 poise. 26.8% by weight of the unsaturated polyester resin, 2 powder inorganic agents
A mixture of 9.5% by weight and 0.27% by weight of a curing agent, 42.9% by weight of translucent amorphous inorganic material, 0.55% by weight of flakes, and 0.54% by weight of glass fiber. % And mixed the prepared molding material with the molding surface b of the female mold b2.
It is cast in a molding space b3 between 2'and the transparent surface layer 1, heat-cured, and then cooled to form a layer (FIG. 4).

The unsaturated polyester resin is colored and transparent,
There is no problem even if it is colored and translucent, and when it is colored, it synergizes with the coloring of the back layer 3 made of FRP, which will be described later, to express a deeper shade.

The translucent amorphous inorganic material 2a has a particle size of 0.
Colorless and transparent or colored transparent glass particles having a diameter of 5 μm to 5 mm, a refractive index of 1.56, a specific gravity of 2.59, and a bulk specific gravity of 1.1 to 1.3, and have fine cracks 2a ′ in a crack shape and are transparent. A light ray diffused and reflected in various directions and a light ray transmitted from the entire outer surface are generated by the minute cracks 2a ′ depending on the light transmission angle from the surface layer 1, and the diffused reflection and transmission of the light ray are further repeated as it goes deeper. And deepest FRP
The back layer 3 made of light is transmitted.

The flakes 2b have a well-known structure in which an iris color exposing thin film layer (not shown) is applied to the surface of a small piece of a transparent polyester film (not shown) having a size of about 3 mm to 5 mm square. It is bent and deformed in two-dimensional and three-dimensional directions by rubbing the upper and lower nets in a state of being placed between the nets, and various iris colors are expressed depending on the incident angle of light. . By the way,
The iris color exposure thin film layer is an iris compound thin film layer in the present embodiment, and examples thereof include thin films of zinc sulfide, bismuth oxide, antimony oxide, titanium oxide, silicon oxide, zinc oxide, etc. Is formed by pressing powder of about 70 to 95% by weight, and it is a normal vapor deposition method such as resistance heating method, high frequency induction heating method, electron beam heating method, etc. with a submicron unit thickness for transparent polyester film. Is formed by. Although not shown, an interference thin film which causes the iris color exposure thin film layer of the flakes 2b to optically interfere may be used.

The glass fiber 2c has a length of 1.5 mm and a fiber diameter of about 1.0 μm, and the translucent irregularly shaped granular inorganic material 2 is used.
a and the flakes 2b are prevented from settling, and the bulk density per unit volume of the irregularly shaped granular inorganic material 2a and flakes 2b is moderated. In this embodiment, as described above, 0.5
As a result of mixing 4% by weight, the bulk density of the amorphous granular inorganic material 2a is about 86%.

The intermediate layer 2 is evenly poured into the molding space b3 and then heated at 40 ° C. or higher for about 30 minutes to generate heat (molding exothermic temperature of 60 ° C. or higher) and wait for cooling before demolding. And then layered. In this example, the mold B was heated at 60 degrees Celsius. It should be noted that even if the molding material is heated to a desired temperature in advance and further heated to 40 ° C. or more, or the molding die B is heated to 40 ° C. or more after injecting the molding material at room temperature. Has not changed.

The coefficient of thermal expansion of the unsaturated polyester resin cured product A'is 17.40 × 10 ^-5 , and the coefficient of thermal expansion of the translucent amorphous amorphous inorganic material 2a is 0.87 × 10 ^-5. The unsaturated polyester resin largely shrinks about 5 times as much as the temperature difference between the molding heat generation temperature and the room temperature, and the sealing crack 2d is naturally formed at the boundary with the cured product A'of the unsaturated polyester resin (FIG. 2). ). The temperature difference is optimally 35 ° C. or higher, and if the temperature difference is lower than 35 ° C., the sealing crack 2d may not be surely formed at the boundary with the irregularly shaped inorganic material, which is not preferable.

After cooling, the female mold b2 is removed, and the back layer 3 made of FRP is applied to the molded body A "(FIG. 5).

The FRP back layer 3 is obtained by impregnating glass fiber with a resin composition prepared by adding a curing agent, an accelerator, a coloring pigment and the like to an unsaturated polyester resin. Applying a lining to the back surface of the, wait for natural curing and remove from the male mold b1 to form a layer.
It is also possible to form the back layer 3 made of a material on the molding surface b2 'of the female mold b2 in advance and to integrate the cast intermediate layer 2 as a medium.

Next, the operation of the molded artificial marble A of this embodiment and the operation of the manufacturing method thereof will be described. The light transmitted through the transparent surface layer 1 to the intermediate layer 2 has fine crack-like cracks 2a 'formed on the transparent amorphous amorphous inorganic material 2a.
The light is transmitted through the irregularly shaped granular inorganic material 2a while being diffusely reflected in various directions depending on the incident light angle, and further diffused by the sealing crack 2d formed at the boundary with the unsaturated polyester resin cured product A '. It reflects and reaches the back layer 3,
In addition to coloring (color) of the back layer 3, a brilliant appearance in which depth and glitter are coexisted is developed (FIG. 2). At that time, the folded and deformed flakes 2b, which are obtained by applying the iris color exposure thin film layer to the transparent polyester film, may be scattered around the sealing cracks 2d partially or in the irregular granular inorganic agent 2a. Embedded in a hardening agent A'of a translucent or transparent unsaturated polyester resin, and cracks 2a 'and sealing cracks 2 are formed in the flakes 2b.
The embedded form in which the light diffusely reflected or transmitted through d is reflected,
In addition to the addition of natural conditions such as bending shapes, the various shades of the seven iris colors are revealed to create the same aesthetic as the natural stone opal. In addition, even when artificial marble is a molding object other than a flat plate, such as a bathtub, the translucent irregular-shaped granular inorganic material 2a and the translucent amorphous inorganic material 2a can be obtained by adding the viscosity of the unsaturated polyester resin and a small amount of the glass fiber 2c. Flakes 2
The flow density and sedimentation of b are not caused, and the bulk density per unit volume is uniformly distributed over the entire area.
(0 degree or more), the sealing crack 2c is surely formed at the boundary with the cured product A'of the unsaturated polyester resin.

When one or both of the intermediate layer 2 and the translucent irregular-shaped granular inorganic material 2a are colored and transparent, they are skillfully fused with the coloring of the back layer 3 to give a glittering brilliance. It is possible to express innovative colors with depth and taste. Of course, the back layer 3 may be colored white and the intermediate layer 2 and the amorphous granular inorganic material 2a may be used to create a color tone.

[Brief description of drawings]

FIG. 1 is a vertical sectional view of an embodiment of claim 1.

FIG. 2 is an enlarged cross-sectional view of a main part of FIG.

FIG. 3 is a vertical cross-sectional view showing a state in which a transparent surface layer is formed on the molding die in the embodiment of claim 2.

FIG. 4 is a vertical cross-sectional view showing a state in which an intermediate layer is laminated on a transparent surface layer.

FIG. 5 is a vertical cross-sectional view showing a state in which a back layer made of FRP is laminated.

[Explanation of symbols]

A: Artificial marble 1: Transparent surface layer 2: Intermediate layer 3: Back layer 2a: Translucent irregularly shaped granular inorganic material 2a ': Crack (crack of irregularly shaped granular inorganic material) 2b: Flake-like material 2c: Glass fiber B: Mold 2d: Seal crack A ": Mold

Continuation of front page (51) Int.Cl. ⁵ Identification code Office reference number FI technical display area B29K 105: 06

Claims (2)

[Claims] 1. An artificial marble comprising a transparent surface layer, an intermediate layer made of resin concrete, and a back layer made of FRP, wherein the intermediate layer is a translucent amorphous amorphous inorganic material having cracks and a surface. It is a transparent or semi-transparent layer that has a mixture of bent and deformed flakes with an iris color exposure thin film layer and has fine sealing cracks at the boundary with an amorphous granular inorganic material. Artificial marble to be. 2. A production method for producing an artificial marble having a three-layer structure of a transparent surface layer, an intermediate layer made of resin concrete, and a back layer made of FRP by a casting method. Is layered on the surface of the mold, and the intermediate layer made of resin concrete is coated with a desired amount of translucent irregularly shaped granular inorganic material that has cracks in the unsaturated polyester resin component together with a curing agent, etc. and an iris color exposure thin film layer on the surface. Prepared by mixing layers of bent and deformed flakes as well as a small amount of glass fiber, the mixture having a viscosity of 50 at 25 degrees Celsius.
A transparent or semi-transparent molding material having a poise of 0 to 1000 poise is cast into a molding die, the molding material is heat-cured to a molding heat temperature of 60 degrees Celsius or more, and then heat-cured and then cooled. The FRP back layer is pre-layered on a molding die or is layered on the above-mentioned heat-cured shaped body, which is a method for producing artificial marble.