JPH0716850A - Production of artificial stone decorative panel - Google Patents

Abstract

PURPOSE:To obtain an artificial stone decorative panel having the same appearance as a natural stone, having high strength, generating no warpage and excellent in waterproofness. CONSTITUTION:A resin compsn. 2 containing a thermosetting resin, a granular colorant and a filler is injected into a casting mold 1 and a fibrous article 3 impregnated with a thermosetting resin is laminated on the layer of the resin compsn. 2 and the whole is cured to be demolded.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method of manufacturing an artificial stone decorative panel used for floors and wall materials of bathrooms and the like which require waterproofness.

[0002]

2. Description of the Related Art Conventionally, as a waterproof decorative panel used for bathroom floors, wall surfaces, etc., a mold is made of SMC in which glass fiber, unsaturated polyester, a filler and a coloring material are mixed in a sheet form. Using a method of hot pressing with a press, spraying up glass fiber and unsaturated polyester resin,
Alternatively, a reinforced plastic panel obtained by molding by hand layup.

A decorative panel formed by hot-pressing a thermosetting resin-impregnated paper, which is an inorganic board material such as an asbestos-cement board or a calcium silicate board impregnated with diallyl phthalate resin or polyester resin.

After subjecting the surface of the inorganic plate material to a base coloring treatment,
A decorative panel in which a paint such as acrylic resin or acrylic urethane resin is applied and the coating film is cured by heating or UV irradiation.

After undercoating the surface of an inorganic plate material or a reinforced plastics substrate, an aqueous coating material made of acrylic resin emulsion containing colored particles is prepared for each color,
There has been a method of applying a coating using a multi-head spray gun or the like and drying it to form a coating film having a stone pattern.

[0006]

Although the decorative panels manufactured by the conventional manufacturing methods have peculiar characteristics caused by the difference in materials and manufacturing processes, in each method,
It has problems in design, durability, manufacturing process, etc.
It was not always satisfactory.

The reinforced plastics panel formed by molding glass fiber and unsaturated polyester resin is lightweight and has high strength and can easily be applied to various shapes, but it is difficult to form a complicated color pattern such as a stone pattern. It was

[0008] In a decorative panel obtained by thermocompressing thermosetting impregnated paper on an inorganic plate material such as an asbestos cement board, a desired pattern can be attached to the decorative paper by printing, but the texture of the stone material is sufficient. It was difficult to express. Further, since the thermosetting resin-impregnated paper has a thin layer, it has a difficulty in abrasion resistance in horizontal applications, and impact resistance is not always satisfactory.

After subjecting the surface of the inorganic plate material to a base coloring treatment,
A decorative panel coated with acrylic resin and cured by UV irradiation has improved surface physical properties compared to the one molded with thermosetting resin-impregnated paper, but it is difficult to express the appearance of stones and the like. , The impact resistance was not sufficient.

In a method of preparing a coating material such as an acrylic emulsion containing colored particles on an inorganic plate material or a reinforced plastics base material for each color and performing spray coating with a multi-head spray gun or the like, design characteristics such as expression of stones are not obtained. Excellent,
The manufacturing process required manpower and skill, and there was a problem in terms of mass productivity.

Further, even if a resin composition obtained by adding colored resin particles, natural stone particles, powder filler and the like to an unsaturated polyester resin is poured into a casting mold, a panel having a stone appearance can be obtained, but the resin and granular materials are used. If the difference in the specific gravity of the objects is large, the particles tend to settle, resulting in non-uniform dispersion such as layer separation.
As a result, the panel is liable to warp and has a drawback that it is inferior in impact resistance, and in particular, it has been a problem in a bathroom floor panel or the like which is required to be warped-free.

According to the present invention, a resin composition containing a thermosetting resin, a granular colorant, and a filler is cast into a mold, and a fibrous sheet impregnated with the thermosetting resin is laminated. ,
It has the appearance of natural stone, has high strength and does not cause warp,
The purpose of the invention is to obtain an artificial stone decorative panel having excellent waterproofness.

[0013]

According to the present invention, a resin composition containing a thermosetting resin, a granular colorant and a filler is injected as a decorative layer into a casting mold, and then the resin composition is applied onto the resin composition. A method for producing an artificial stone decorative panel, which comprises laminating fibrous materials impregnated with a thermosetting resin as a base material layer, curing the fibrous material, and demolding the fibrous material. In particular, a decorative layer in a casting mold. The thermosetting resin of the resin composition to be injected as is composed of an unsaturated melamine resin and an unsaturated polyester resin, and a glass fiber sheet is impregnated with an unsaturated melamine resin and an unsaturated polyester resin as a base material layer. This is a method for producing an artificial decorative panel, which is characterized by laminating a tongue-shaped object.

The casting mold used in the present invention is an open mold made of metal or reinforced plastics. The mold surface has a desired surface finish such as gloss, semi-gloss, and matte finish, and a release agent treatment is performed prior to the casting process.

As a method of treating the release agent, a film is formed by applying wax or silicone resin and wiping it off, or by applying an aqueous solution of polyvinyl alcohol and drying it.

The thermosetting resin used in the present invention is a resin such as an unsaturated melamine resin, an unsaturated polyester resin or a methylmethacrylate resin, or a combination of at least two kinds thereof.

The unsaturated melamine resin of the present invention is a prepolymer having an average molecular weight of 200 to 8000, which is synthesized from melamine, paraformaldehyde, and 2-hydroxyethyl (meth) acrylate by a condensation reaction.

The unsaturated polyester resin in the present invention is obtained by reacting an unsaturated polybasic acid, a resin obtained by heating esterification of a saturated polybasic acid and glycol, or an epoxy resin with (meth) acrylic acid. It is a liquid resin obtained by dissolving the thus obtained vinyl ester resin in a vinyl monomer that acts as a crosslinking agent.

Maleic acid, fumaric acid and the like are used as the unsaturated polybasic acid. As the saturated polybasic acid, phthalic anhydride, isophthalic acid, terephthalic acid, adipic acid, etc. are used. Particularly, by using isophthalic acid as the saturated polybasic acid, physical properties such as heat resistance can be improved. As glycols, ethylene glycol, propylene glycol, diethylene glycol, etc. are generally used. As the vinyl monomer, styrene monomer, methyl methacrylate monomer, etc. are used.

Since the unsaturated melamine resin and the unsaturated polyester are polymerized by a common curing agent and curing accelerator, the curing accelerator applied to the molding die can be effectively applied to both resins.

An organic peroxide is used as the curing agent. In room temperature curing, that is, curing at a relatively low temperature of about 50 ° C. or lower, a substance that decomposes a catalyst by a redox reaction and promotes radical generation is used as a curing accelerator.

As the combination of the curing agent and the curing accelerator in the room temperature curing, an organic acid salt of methyl ethyl ketone peroxide and cobalt, or benzoylperoxide and cobalt naphthenate is generally used.

The components of the resin used for casting are composed of the above-mentioned unsaturated melamine resin, unsaturated polyester resin, etc., and granular colorant, filler, curing agent, curing accelerator and the like.

The granular colorant is used not only to obtain a coloring effect but also to give a pattern and texture like natural stone, and is a granule of granite, a granule of colored resin, etc., having a particle diameter of 300 μm.
Those having a size of m to 5 mm are suitable and have a function as a filler together with a coloring effect. In particular, a texture close to that of natural stone can be obtained by using several kinds of colored particles. Further, it is possible to use a coloring agent such as a pigment together if necessary. As the filler, powder of aluminum hydroxide, silica, calcium carbonate, glass or the like is used.

The ratio of the resin to the filler containing the granular colorant in the present invention is generally 20 to 4 by weight.
The range of 0 part and the filler containing the granular colorant is preferably 60 to 80 parts. When the amount of the resin component is 20 parts or more, the fluidity of the resin composition decreases and the defoaming property decreases. When the content of the filler is 60 parts or less, shrinkage due to shrinkage, deterioration of texture, increase in material price, etc. are not preferable, but the compounding ratio of these varies depending on resin viscosity, type of filler, particle size, etc. Can be selected.

The resin composition is usually mixed with a closed stirrer until the material is uniformly decomposed. It is desirable to perform this stirring while depressurizing and defoaming. The resin composition after stirring is poured into a mold, and the contained air is removed by vibration or the like.

Next, as a method for laminating the base material layer, a glass fiber chop strand mat or the like is placed on the cast material and repeatedly pressed to impregnate the resin component of the resin composition for lamination, and the unsaturated polyester resin is used. A reinforced plastics layer is formed and cured on the cast resin composition by a method of laminating a glass fiber mat impregnated with the above, or a method of spraying up using a glass fiber and a resin. By forming the base material layer made of the reinforced plastics layer, the strength of the panel is improved, and the resin and the granular colorant are prevented from being separated from each other due to the difference in specific gravity or being made into a gradient material, which is useful for preventing warpage. After curing, the artificial stone decorative panel, which is a molded product, is removed from the casting mold and taken out.

[0028]

【Example】

Example 1 An example of the present invention will be described below with reference to the drawings.
FIG. 1 is a cross-sectional view showing an example of a state in which a resin composition 2 is cast into an open type casting mold 1 and a fibrous material 3 impregnated with a thermosetting resin is further laminated.

FIG. 2 is a sectional view showing an example of the material constitution of the artificial stone decorative panel 4 taken out from the casting mold.

A stainless steel open-type casting mold 1 of the floor panel shape of the unit bath bathroom is provided on the mold surface.
Apply the resin release agent thinly and uniformly. 6 parts of melamine methacrylate prepolymer obtained by condensing melamine, paraformaldehyde, and 2-hydroxyethyl (meth) acrylate as resin composition 2 constituting the decorative layer, fumaric acid, phthalic anhydride, and isophthalate Unsaturated polyester resin 24 consisting of 50% styrene monomer solution of polyester obtained by condensing acid and propylene glycol
Part, 20 to 30 mesh granules of 20-30 mesh granules of a mixed resin cured product composed of unsaturated melamine resin colored in gray with carbon black and titanium oxide and the same amount of unsaturated polyester resin, colored in brown with iron oxide 20 parts of the mixed resin cured product of 10 to 30 mesh granules, 25 parts of the mixed resin cured product of 10 to 30 mesh granules colored white with titanium oxide, 5 parts of aluminum hydroxide, a curing agent As a curing accelerator, 0.4 parts of methyl ethyl ketone peroxide 55% dibutyl phthalate solution and 0.2 parts of cobalt naphthenate 6% styrene monomer solution are added, and the internal pressure is reduced to Hg 100 mm by using a reduced pressure stirring mixer. While stirring, the mixture is defoamed for 15 minutes to prepare a uniform resin composition 2.

This resin composition 2 was poured into a casting mold so as to have a thickness of 7 mm, vibrated with a vibrator for 1 minute, defoamed, and placed on a horizontal table. Overlay the glass fiber chop strand mat on the resin composition 2,
The resin liquid is permeated and impregnated while pressing.

In this way, a reinforced plastics layer having a thickness of about 1 mm, which is the fibrous material 3 impregnated with the thermosetting resin, is laminated and then left standing at a temperature of 30 ° C. for 2 hours to be cured and cast molding. The mold was removed from the mold 1, and aftercure was performed in a furnace at 100 ° C. for 2 hours to obtain an artificial stone decorative panel used for the floor of the unit bath bathroom.

[0033]

EFFECTS OF THE INVENTION Since the decorative layer is cast with a resin composition comprising a thermosetting resin, a granular colorant, and a filler, the texture of natural stone can be obtained. In particular, unsaturated melamine is used as a thermosetting resin component. By copolymerizing the resin and the unsaturated polyester resin, the weather resistance is remarkably improved as compared with the polyester alone.

Further, since the reinforced plastics layer as the base material layer is made into a composite and integrated, the strength is improved and the sedimentation of the granular colorant and the occurrence of warpage due to layer separation can be prevented. .

[Brief description of drawings]

FIG. 1 is a cross-sectional view showing an example of a structure in a casting mold of an artificial stone decorative panel of the present invention.

FIG. 2 is a cross-sectional view showing an example of the structure of the artificial stone decorative panel of the present invention.

FIG. 3 is a perspective view showing an example of the structure of the artificial stone decorative panel of the present invention.

[Explanation of symbols]

 1 Casting Mold 2 Resin Composition 3 Fibrous Material Impregnated with Thermosetting Resin 4 Artificial Stone Decorative Panel 5 Granular Colorant

Continuation of front page (51) Int.Cl. ⁶ Identification number Office reference number FI technical display area B29K 105: 06 B29L 31:10

Claims (2)

[Claims] 1. A resin composition containing a thermosetting resin, a granular colorant, and a filler is injected as a decorative layer into a casting mold, and then thermoset as a base material layer on the resin composition. A method of manufacturing an artificial stone decorative panel, which comprises laminating fibrous materials impregnated with a functional resin, hardening the fibrous materials, and demolding. 2. A thermosetting resin of a resin composition to be injected as a decorative layer into a casting mold comprises an unsaturated melamine resin and an unsaturated polyester resin, and an unsaturated melamine resin and an unsaturated polyester as a base material layer. The method for producing an artificial stone decorative panel according to claim 1, wherein a sheet-shaped material obtained by impregnating a glass fiber sheet with a resin is laminated.