JPH0788851A - Preparation of artificial store - Google Patents

Abstract

PURPOSE:To shorten a manufacturing work for an artificial stone by a method wherein a base material is placed in the bottom force of a mold and the base material is applied to the inner face of the top force in a thin film-like shape and these base materials are deformed and after the base material on the top force is cured, the top force is assembled to the bottom force in an uncured state of the base material. CONSTITUTION:A base material 13 made of a resin compsn. prepd. by mixing an unsatd. polyester resin, aluminum hydroxide and an oxidizing agent is applied with a specified thickness to the recessed part 10 of the bottom force 11 of a mold. In parallel with this, base material 15 with the same compsn. is applied to the surface of a top force 12 in a thin film-like shape. Then, the top and bottom forces 11 and 12 are vibrated to defoam air bubbles in both base materials 13 and 15. In addition, the base material 15 are irradiated and heated with far infrared rays to bring it into a semi-cured condition and the forces are assembled while the bottom force is in a uncured state. It is possible thereby to use the surface and the rear face with no pinhole within one casting time and to shorten the working time.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing an artificial stone capable of producing a product having a beautiful appearance in which pinholes cannot be seen from the surface of the product.

[0002]

2. Description of the Related Art Conventionally, as a method for manufacturing an artificial stone for the above purpose, there are methods described in Japanese Patent Publication No. 3-18806 and Japanese Patent Publication No. 2-33499.

In the method for producing an artificial stone described in Japanese Patent Publication No. 3-18806, a molding material is obtained by adding an auxiliary material such as a pigment to a main material made of a resin material such as an unsaturated polyester resin. 20% to 80% of the volume of the receiving mold is added with a curing agent and injected into the receiving mold, and the receiving mold is vibrated slightly until the injection material is semi-cured. The air bubbles inside are moved toward the injection surface, and after that, a curing agent is added to the remaining amount of the molding material to replenish the semi-cured body so that the inside of the mold is filled, and then the same The mold and pressing die are combined and turned upside down, and the combined mold is vibrated slightly to move the bubbles in the replenishment material toward the replenishment interface. It is characterized in that the molded article is removed from the mold.

On the other hand, in the method for producing an artificial stone described in Japanese Patent Publication No. 2-33499, one or several kinds of unsaturated polyester blends for patterns are put in an appropriate size in an unsaturated polyester blend for base color. Then, stir this and repeat the required number of times to disperse the unsaturated polyester mixture for pattern in the unsaturated polyester mixture for base color, and put the obtained molding material in the hopper having the slit-shaped supply port. , The slit-shaped supply port supplies the molding material to each of the front mold and the back mold that form a pair of molded products in a continuous falling state from the open side, and the molding material is spread over the entire mold surface. First, the back (or front) mold is made to be in a semi-cured state, and the back (or front) mold in the semi-cured state is inverted and combined with the uncured front (or back) mold to form a front mold product Integrated with the back mold product Characterized in that to form a flow pattern shiny on both sides of.

[0005]

However, the above-mentioned method for producing an artificial stone still has the following problems to be solved.

That is, in the method for manufacturing an artificial stone described in Japanese Patent Publication No. 3-18806, the second casting can be performed only after the one first cast in the lower die is half cured. There is a lot of time loss because we have to wait for the first half-cure. Also, since the lower mold is often a heavy mold, it is a large-scale device-wide operation to invert and degas the entire mold after assembling the upper mold on the lower mold, and therefore manufacturing is not possible. Limited to small products. Further, when the upper mold is covered, air enters the interface between the mold and the base material, which makes it difficult to remove bubbles. On the other hand, in the method for manufacturing an artificial stone described in Japanese Examined Patent Publication No. 2-33499, the upper mold and the lower mold are each filled with the material and then defoamed. Since the materials of the respective molds are not joined unless they are assembled in a semi-cured and uncured state, the start time of the casting must be shifted between the upper mold and the lower mold, resulting in loss time. On the other hand, in order to match the start and end, it is necessary to adjust the temperature difference of each mold, which is a large scale for the device,
Products will be limited to small products. Furthermore, when casting, it is difficult to reduce the thickness (to 1 to 5 mm or less) and to make the thickness uniform. Also, the upper mold
Since both lower molds were limited to concave molds, a seam for matching the molds appeared in the center of the product, which also reduced the product value.

It is an object of the present invention to provide a method for manufacturing an artificial stone that can solve the above problems.

[0008]

According to the present invention, a concave lower mold is filled with a base material consisting of a resin material and a filler, and the upper mold having a flat plate or a convex surface is provided on the inner surface side thereof. Apply a base material of the same material as the base material in a thin film, degas bubbles from each base material, and cure the upper base material while the base material cast in the lower mold is uncured After that, it is assembled in a lower mold and the base materials of the upper mold and the lower mold are joined to each other to manufacture an artificial stone.

According to the present invention, a base material composed of a resin material and a filler is applied in a thin film on the inner surfaces of the upper and lower molds in a flat plate shape and defoamed, so that either of the upper and lower mold bases can be removed. The present invention relates to a method for manufacturing an artificial stone, characterized in that an upper mold and a lower mold are combined in an uncured material, and the base materials are joined together to manufacture the artificial stone.

The present invention further provides, in the above-described method for manufacturing an artificial stone, a heater, which comprises a base material obtained by applying a thin film on either the upper mold having the flat plate or the convex shape or the upper and lower molds having the flat plate shape. It is also characterized in that it is cured by heating with a heat exchanger or the like, and that the manufacturing method is carried out after applying a gel coat to the inner surfaces of the upper mold and the lower mold.

[0011]

[Operation] Air from the base material filled in the lower mold rises to the upper part at the time of casting, and pinholes are generated on the upper surface (rear surface).
Similarly, pinholes are generated on the upper surface (back surface) of the resin applied in a thin film on the upper mold. By matching the back surfaces together, the pinhole is confined to the inner surface and does not appear on the front side.

The base material formed into a thin film can be rapidly defoamed and can be directly irradiated with a far-infrared heater or a microwave heater, which has a fast curing power, to be cured. In a time, it is possible to manufacture an artificial stone that can be used on both sides. Further, even if the base material is directly irradiated with a heating means having a rapid curing ability, the base material is in the form of a thin film, so that the whole is uniformly cured and is not deformed such as distorted or bent.

[0013]

EXAMPLES Hereinafter, the method for producing an artificial stone according to the present invention will be specifically described with reference to the examples shown in the accompanying drawings. In addition,
In this embodiment, a flat counter A having a length of 4 m, a width of 600 mm and a thickness of 12 mm is manufactured.

(Embodiment 1) As shown in FIG.
A lower mold 11 having a rectangular shape and a flat upper mold 12 as shown in FIG. 1 (b) are prepared.

As shown in FIG. 1 (a), an unsaturated polyester resin (30% by weight), aluminum hydroxide (70% by weight) and a curing agent (1% by weight) are placed in the recess 10 of the lower mold 11. The base material 13 made of the resin composition obtained by mixing and is filled up to a constant thickness (for example, 10 mm).

On the other hand, in parallel with the above work, as shown in FIG. 1 (b), a base material 15 made of the same or similar composition as the above-mentioned base material 13 is sprayed on the surface of the upper mold 12 by a spray gun 14.
To a thickness of 2 mm.

As shown in FIGS. 1 (c) and 1 (d), the upper and lower molds 11, 12
Then, vibration is applied to the base material 13 and the base material 15 in the recess 10 by using a vibrator or the like (not shown). Here, some of the bubbles in the base material 13 will move to the surface side of the base material 13, and the bubbles in the base material 14 will be completely defoamed because the base material 14 is a thin film. It will be.

Thereafter, as shown in FIG. 1 (e), the base material
From the side coated with the base material 14 only to 14
Using a far-infrared heater until
Irradiate far infrared rays and heat.

Next, as shown in FIG. 1 (f), the upper mold 12 is assembled to the lower mold 11, and is cured using a heater or the like as shown in FIG. 1 (g) or in a natural state.

Thereafter, as shown in FIG. 1 (h), the upper and lower molds 1
Remove the mold from 1,12 and take out the counter A as a product.

(Embodiment 2) As shown in FIG.
Then, apply gel coat resin 30 with a spray gun 40 and cure it, and then spray gun 40 with unsaturated polyester resin (30 wt%) and aluminum hydroxide (70 wt%).
And a hardener (1% by weight) are mixed to apply a base material 24 made of a resin composition having a thickness of 3 mm.

As shown in FIG. 2 (b), the upper mold 22 is vibrated by using a vibrator or the like (not shown) to remove bubbles in the base material 24. It is not necessary to completely defoam,
As shown in FIG. 2 (c), it is sufficient that some of the bubbles are collected on one surface of the base material 24.

After that, as shown in FIG. 2 (d), the base material
From the side where the base material 24 is applied to 24, the microwave is irradiated and heated for 10 minutes using a microwave heater until the base material 24 is in a semi-cured state.

Further, as shown in FIG. 2 (e), the gel coat resin is applied to the lower mold 21 with the spray gun 40 as in the case of the upper mold 22.
31 was applied and cured, and then an unsaturated polyester resin (30% by weight), aluminum hydroxide (70% by weight), and a curing agent (1% by weight) were mixed with the spray gun 13. A base material 25 made of a resin composition is applied in a thickness of 3 mm.

As shown in FIG. 2 (f), the lower mold 21 is vibrated by using a vibrator (not shown) or the like to remove bubbles in the base material 25. It is not necessary to completely defoam,
As shown in FIG. 2 (g), it is sufficient that some of the bubbles collect on one surface of the base material 25.

Thereafter, as shown in FIG. 2 (h), the lower mold 21 coated with the uncured base material 25 is assembled with the upper mold 22 coated with the semi-cured base material 24 to form a base material. 24,25 are integrated and hardened.

The upper and lower molds 21 and 22 are peeled off from the integrated product, the mold is removed, and a desired size is cut using a cutter to manufacture a counter A as shown in FIG. 2 (i).

[0028]

[Effect] As described above, the present invention has the following effects.

A base material is applied in a thin film on the inner surface of the upper mold,
By combining with the lower mold, it is possible to manufacture products with beautiful appearance without pinholes on the front and back surfaces. Further, since quick defoaming and effects can be achieved, it is possible to mold an artificial stone product that can be used on both sides within the molding time of one-time casting. Since it is possible to use a far infrared heater or a microwave heater, quick curing can be done, adjustment of semi-cured or uncured and timing of curing by molding can be freely and easily performed, saving time and work. It is possible to improve efficiency.

Since the upper die has the shape of a flat plate or a convex surface, the joint of the upper and lower dies does not come to the center of the product which is easily noticeable, so that an artificial stone product having a good appearance can be obtained.

By the simple method of applying the base material in a thin film shape to the upper and lower molds formed in a flat plate shape, defoaming, and matching and hardening, a flat plate-shaped artificial stone product which can be used on both sides is obtained. To be

By applying a gel coat to the inner surface of the upper and lower molds, a transparent feeling can be obtained and an artificial stone product having a glossy surface can be obtained.

[Brief description of drawings]

FIG. 1 is a process explanatory diagram of a method for manufacturing an artificial stone according to a first embodiment of the present invention.

FIG. 2 is a process explanatory view of the method for manufacturing an artificial stone according to the second embodiment.

[Explanation of symbols]

 A Counter 11 Lower mold 12 Upper mold 13 Base material 15 Base material 21 Lower mold 22 Upper mold 24 Base material 25 Base material

─────────────────────────────────────────────────── ─── Continuation of the front page (51) Int.Cl. ⁶ Identification code Internal reference number FI technical display location B29L 31:10

Claims (4)

[Claims] 1. A concave lower mold (11) is filled with a base material (13) composed of a resin material and a filler, and is provided on the inner surface side of an upper mold (12) having a flat or convex surface. Apply the base material (15) of substantially the same material as the base material (13) in a thin film,
Remove the bubbles from each base material (13) (15)
While the base material (13) cast in (11) is uncured, the upper mold
After hardening the base material (15) of (12), it is assembled into the lower mold (11), and the base materials (13) and (15) of the upper mold (12) and the lower mold (11) are joined to each other. A method for producing an artificial stone, which comprises: 2. A base material (24) (25) consisting of a resin material and a filler is applied in a thin film to the inner surfaces of the flat upper and lower molds (21) (22) and is defoamed. , The upper and lower molds (21) and (22) are combined while one of the upper and lower mold base materials (24) and (25) is uncured, and the base materials (24) and (25) are joined together to manufacture an artificial stone. A method for manufacturing an artificial stone, which comprises: 3. A base material (24) (25) coated in a thin film on either the upper mold (12) having the flat plate or the convex shape or the upper and lower molds (21) (22) having the flat plate shape. The method for producing an artificial stone according to claim 1 or 2, wherein the heating is performed by heating using a heating unit to cure the stone. 4. The manufacturing method is performed after applying a gel coat to the inner surfaces of the upper molds (12) (22) and the lower molds (11) (21) and curing them. The method for producing an artificial stone according to claim 1 or 2.