JPH0691664A - Artificial marble and manufacture thereof - Google Patents

Abstract

PURPOSE:To obtain an artificial marble of a simple structure for representing a unique sense of beauty without raising cost of a material and without complicating molding steps by disposing a transparent resin concrete layer for representing a pattern formed with thick parts and thin parts as light transmission layers to a layer of a back side. CONSTITUTION:A transparent resin concrete layer 1 of an artificial marble A is formed by kneading aerogel as thixotropic agent and glass frit as filler with colorless transparent or colorless translucent unsaturated polyester resin and injecting a molding material in which thixotropy index is regulated to 3.0-5.0 and viscosity coefficient is regulated to 80-2100 poise in a gelled or completely cured transparent gel coating layer 2. Compressed air is sprayed before the molding material is gelled to form an undulated part 31 which alternately has raised thick parts 11 and settled thin parts 21 over an entire area while moving under pressure a desired part in longitudinal and/or lateral directions. Thus, a back reinforced layer 3 is formed by waiting belling or complete curing of the layer 1.

Description

Detailed Description of the Invention

[0001]

TECHNICAL FIELD The present invention relates to an artificial marble and a method for producing the same.

[0002]

2. Description of the Related Art Conventionally, a molding material (resin concrete) prepared by mixing a desired amount of a filler with an unsaturated polyester resin is mixed with an inorganic material for patterning, and this is cured to form a transparent intermediate layer. Formed artificial marble or molding material (resin concrete) for each color base material required to express a marble pattern is added to unsaturated polyester resin together with a filler and a predetermined pigment to adjust, and the molding material is piled up. Artificial marble or the like is widely used in which an intermediate layer is formed by applying the composition to the above and curing it. These artificial marbles have a profound feeling, and by arbitrarily selecting the type of inorganic material to be mixed, various artificial tastes and textures are expressed, and the natural arrangement relationship of the color base material expresses a simulated appearance to marble. Incidentally, in the prior art, unsaturated polyester resin in which mica is scattered (Japanese Patent Publication No. 61-25543) and stones such as granite (Japanese Patent Laid-Open No. 62-1974).
No. 57), further, those having fibers such as vinylon scattered (JP-A-57-123859), and those having glass flakes scattered in scale (JP-A-2-153966).
Japanese Patent Laid-Open Publication No. 63-308), in which a brown base material is cracked between a colorless base material, a brown base material and a green base material (Japanese Patent Publication No. Sho 63-308).
No. 41) has been proposed.

[0003]

By the way, in the prior art, mica and scaly glass flakes express glitter, and vinylon and granite express the unique color decorativeness of the pattern manifester, Furthermore, it is an artificial marble that expresses natural objects by the cooperation of several types of base materials with different shades.

A technical object of the present invention is to express a unique aesthetic feeling with artificial marble having a simple structure for increasing or decreasing the thickness of a transparent layer (resin concrete layer). Still another technical problem is to manufacture an artificial marble that expresses various aesthetic feelings in different atmospheres by freely forming the undulation shape by changing the thickness of the transparent layer (resin concrete layer). .

[0005]

The technical means taken to achieve the above object is a transparent resin for pattern expression, in which a thick portion and a thin portion are formed as a light transmitting layer to a layer on the back side. The gist is that the concrete layers are arranged. Also,
The manufacturing method, before the molding material for the transparent resin concrete layer applied as the surface layer or the back layer of the transparent gel coat layer on the molding die is gelled, compressed air is blown to the molding material to blow a desired portion of the molding material. A transparent resin concrete layer is hardened after forming an uneven undulation portion having a raised thick portion and a sinking thin portion while being pressed in the front-back direction and / or the left-right direction, and the back side layer is a transparent resin. The main point is to form a layer after hardening the concrete layer.

[0006]

According to the above technical means, there are the following actions. (Claim 1) The thick-walled portion serves as a low-transmissive portion that prevents light from passing therethrough, and the thin-walled portion serves as a high-transmissive portion that allows light to pass therethrough. Therefore, the thick portion becomes cloudy white due to the action peculiar to resin concrete, and the thin portion exposes the color of the layer on the back side, and the difference in color tone between the two becomes a pattern. On the other hand, when the transparent resin concrete layer is colored transparent or colored semi-transparent, the coloring of the thick portion is emphasized, while the thin portion does not expose the coloring because light is well transmitted, and the back side Expose the color of the layers. (Claim 2) Before the molding material gels, a concavo-convex undulation portion having alternating thick thick portions and sinking thin portions while being forcedly blown with compressed air to be pressed in the front-rear direction and / or the left-right direction The transparent resin concrete layer that hardens in the molded state has various shapes of undulations that have different undulations depending on conditions such as the location where the compressed air is sprayed, the spray pressure, the distance, and the angle.

[0007]

As described above, according to the present invention, a transparent resin concrete layer having a thick portion which is a low transmission portion which obstructs the transmission of light and a thin portion which is a high transmission portion which transmits light is provided on the back side layer. The three-dimensional beauty is expressed by the simple cross-section structure that is arranged as the light transmission layer of. Therefore, the molding material (resin concrete) is intentionally mixed with an inorganic material for patterning to form a transparent intermediate layer, or the molding material (resin concrete) for each color substrate necessary for expressing a marble pattern is appropriately selected. It is possible to provide an artificial marble having a simple structure that expresses a unique aesthetic feeling without causing a high material cost and complicating a molding process such as forming a middle layer by coating in a heap shape. Further, in the manufacturing method, since the raised thick portion and the settled thin portion forming the pattern are formed by compressed air blown before the transparent resin concrete layer gels, it is similar to a so-called wind ripple. It is possible to lay out a raised thick wall portion and a settled thin wall portion of a desired thickness with a theoretically desired plan view form, rock,
Natural objects such as clouds, flowers and waves, landscapes, and patterns such as pictures can be naturally expressed. Moreover, since the compressed air is used to easily and quickly form the uneven undulations, it is possible to shorten the manufacturing time of the artificial marble and to simplify the labor, thereby contributing to the provision of the inexpensive artificial marble.

[0008]

Embodiments of the present invention will now be described with reference to the drawings. 1 and 2 show a first embodiment of artificial marble, and FIG.
1 to 2 show an artificial marble manufacturing method shown in FIGS. 1 and 2, FIGS. 7 and 8 show a second embodiment of the artificial marble, and FIGS. 9 and 10 show other manufacturing methods. As an example of the above, the manufacturing method of the artificial marble shown in FIGS.

First, the first embodiment will be described together with the manufacturing method. The artificial marble A of the first embodiment shown in FIG. 1 and FIG.
A case where the transparent resin concrete layer 1 is laminated as an intermediate layer is shown, and as a back layer of the surface gel coat layer 2, that is, as an intermediate layer, a thick portion (described below as a raised thick portion) 11 and a thin portion (below) A transparent resin concrete layer 1 having a settling thin portion 21) and a back reinforcing layer 3 directly as a back layer 3
It has a layered structure.

The gel coat layer 2 has a thickness of about 0.3 to 0.5 mm.

The transparent resin concrete layer 1 has a thickness of 0.3-
It is applied as a layer next to the gel coat layer 2 with a thickness of about 1.5 mm.

The back reinforcing layer 3 is composed of a colored transparent or colored opaque resin concrete layer so that the color of the added coloring pigment can be revealed, and the back reinforcing layer 3 is applied with a desired thickness as a reinforcing layer. .

As shown in FIGS. 1 and 2, each of the raised thick-walled portions 11 has a ridge line shape or the like at appropriate intervals over the entire rear surface side which forms a boundary with the back reinforcing layer 3 in the transparent resin concrete layer 1. It is formed so as to have an arbitrary planar view.

As shown in FIGS. 1 and 2, the settling thin-walled portions 21 ... Inevitably are formed in a valley shape or a basin shape between the adjacent raised thick-walled portions 11, 11.

The gel coat layer 2 is prepared by adding a predetermined curing agent, accelerator, etc. to a transparent unsaturated polyester resin, and is coated on the molding surface 100a of the molding die 100 to form a layer ( (Figure 3).

The transparent resin concrete layer 1 was prepared by kneading 100 parts of colorless and transparent or colorless and translucent unsaturated polyester resin with 10 parts of Aerosil as a thixotropic agent and 160 parts of glass frit as a filler. .0-5.
0, a molding material 1'having a viscosity of 80 to 2100 poise is cast on the gelled (semi-cured) or completely cured gel coat layer 2 and compressed before the molding material 1'gelates. Concavo-convex undulations 31 having raised thick-walled parts 11 ...
Are formed over the entire area (FIGS. 4 and 5), and the back reinforcing layer 3 is formed after the transparent resin concrete layer 1 is gelled (semi-cured) or completely cured.

The concavo-convex undulations 31 are transparent in a state before gelation from a nozzle of an air gun (not shown) connected to a compressed air generator (air compressor) (not shown) via an air hose (not shown). By forming compressed air while approaching the molding material 1'of the resin concrete layer 1 at a distance of about 50 to 300 mm while changing the angle as necessary, it is formed into a valley-like or basin-like settling thin-walled portion 21 ... In the front-back direction and /
Alternatively, the molding material 1'compressed (removed) in the left-right direction is used to rationally form the ridge-shaped protruding thick-walled portions 11 ... Having a relatively sharp tip.

As the back reinforcing layer 3, a transparent or opaque molding material 3 ′ prepared by mixing glass frit and a desired coloring pigment in an unsaturated polyester resin is gelled (semi-cured) or completely formed in the transparent resin concrete layer 1. After the curing, it is cast on the transparent resin concrete layer 1 (FIG. 6), and after it is completely cured, it is released from the molding die 100 to mold the artificial marble A.

Next, the operation of the molded artificial marble A of the first embodiment and the operation of the manufacturing method thereof will be described. The light transmitted to the transparent resin concrete layer 1 via the transparent gel coat layer 2 reaches the uneven undulations 31 composed of the raised thick portions 11 ... And the settled thin portions 21. Raised thick portion 11 ... (Fig. 2
The hatched portion (indicated by hatching) has a low light transmittance due to the thickness and exhibits a cloudy color, and the settling thin portion 21 ... The color of is exposed. Therefore, the raised thick-walled portions 11 ... Are formed so as to draw the contours of petals, clouds, etc.,
When it is formed so as to draw a wave crest, that part becomes cloudy, and the other part reveals the background color of the back reinforcing layer 3, so that not only natural objects but also scenery can be clearly embodied. In the case where the back reinforcing layer 3 has a sheet material that reveals a stone tone or the like as its surface layer, the white turbid color of the raised thick portion 11 ... You can also express the feeling. Further, even when the artificial marble is a molding object other than a flat plate, such as a bathtub, the molding material does not flow due to the viscosity and can be molded reliably.

Next, the second embodiment will be described together with the manufacturing method. In the second embodiment, the fine decorative piece 14 is provided as a back side layer between the transparent resin concrete layer 1 and the back reinforcing layer 3.
An example is shown in which the transparent thin film layer 4 in which the transparent thin film layer 4 is mixed is arranged. Since the layers other than the layering of the transparent thin film layer 4 are common to the first embodiment, the description thereof will be omitted.

The transparent thin film layer 4 is prepared by adding a predetermined curing agent, an accelerator and the like to a transparent unsaturated polyester resin and mixing fine gold powder as the fine decorative piece 14 so that the transparent resin concrete layer 1 is a gel. It is sprayed in a fully cured (semi-cured) or completely cured state. This transparent thin film layer 4 is
The transparent resin concrete layer 1 is applied in the same thickness partly or entirely along the uneven portions 31 of the transparent resin concrete layer 1 and waits for gelation (semi-hardening) or complete hardening to form the back reinforcing layer 3 in the same manner as in the first embodiment. It is also layered.

In the artificial marble of the second embodiment, the fine ornamental pieces 14 made of gold powder add a glittering effect to the natural objects and landscapes described in the first embodiment.

Although not shown in the drawing, it does not matter if the transparent resin concrete layer 1 of the first and second embodiments is colored transparent or colored translucent. In this case, while the coloring of the raised thick portion is emphasized, the coloring is not exposed in the sinking thin portion, and conversely, the color of the back side layer 3 or 4 can be exposed. This can be easily achieved by adjusting the addition amount of the color pigment mixed in the transparent resin concrete layer 1 and selecting the thickness of the raised thick portion 11 and the thin settling portion 21.

In this way, the raised thick-walled portions 11 of the transparent resin concrete layer 1 are colored, the back reinforcing layer 3 is colored, and the fine decoration pieces 14 in the transparent thin film layer 4 arranged as necessary cooperate with each other. By the action, more decorative and three-dimensional patterns can be expressed.

The artificial marble according to claim 1, which is not shown in the drawing, does not need heat resistance and is intended for a counter having a transparent resin concrete layer as a surface layer. However, the present invention also includes the case where the uneven portion formed by the gap between the thick portion and the thin portion is formed on the surface side. In this case, the pattern can be enjoyed by touch. Further, regarding the thick portion 11 and the thin portion 21 of the artificial marble of claim 1, before the molding material 1'for the transparent resin concrete layer 1 applied as the surface layer or the intermediate layer to the molding die 100 is gelled, A unique cross-sectional shape formed by using rolls or spatulas for embossing, or by applying the same molding material 1'in a heap shape so as to make it thicker than other thin parts The invention encompasses. Incidentally, it goes without saying that the FRP layer may be used as the back reinforcing layer 3 in the first and second embodiments without using the resin concrete layer.

[Brief description of drawings]

FIG. 1 is a vertical sectional front view of a first embodiment of artificial marble.

FIG. 2 is a plan view of the artificial marble.

FIG. 3 is a vertical sectional front view showing the manufacturing process of FIG. 1 and showing the process of forming a gel coat layer.

FIG. 4 is a vertical cross-sectional front view showing a state in which transparent resin concrete is cast as a layer next to the gel coat layer.

FIG. 5 is a vertical cross-sectional front view showing a state in which compressed air is blown onto the transparent resin concrete before gelling to form a raised thick portion and a settled thin portion.

FIG. 6 is a vertical sectional front view showing a state in which a back reinforcing layer is laminated.

FIG. 7 is a vertical sectional front view of a second embodiment of the artificial marble.

FIG. 8 is a plan view of the artificial marble.

9 is a longitudinal sectional front view showing the manufacturing process of FIG. 7 different from the manufacturing process of FIG. 1, showing a state in which a transparent thin film layer is applied as a layer next to the transparent resin concrete layer.

FIG. 10 is a vertical sectional front view showing a state in which a back reinforcing layer is laminated.

[Explanation of symbols]

A: Artificial marble 1: Transparent resin concrete layer 2: Gel coat layer 3: Back side layer (back reinforcement layer) 4: Back side layer (transparent thin film layer) 100: Mold 11: Thick part (protrusion thick part) ) 21: Thin part (settling thin part) 31: Uneven surface

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Claims (2)

[Claims] 1. An artificial marble characterized in that a transparent resin concrete layer for pattern expression, in which a thick portion and a thin portion are formed, is arranged as a light transmitting layer to a layer on the back side. 2. A desired portion of the molding material is sprayed with compressed air before the molding material for the transparent resin concrete layer applied to the molding die as the surface layer or the backing layer of the transparent gel coat layer is gelled. After forming a concavo-convex undulating portion having a thick-walled raised portion and a thin-walled settled portion while pressing in the front-back direction and / or the left-right direction, the transparent resin concrete layer is cured, and the back layer is transparent. A method for producing an artificial marble, characterized in that the resin concrete layer is layered after hardening.