JPH08267648A - Artificial marble composite panel - Google Patents

Abstract

PURPOSE: To provide an artificial marble composite panel being useful as construction materials such as flooring materials and wall materials. CONSTITUTION: An artificial marble composite panel is prepd. by bonding and integrally laminating a primary resin-stone powder mixture layer 1 and a secondary resin-stone powder mixture layer 2. Therefore, it is lightweight and exhibits excellent mechanical strength, water resistance and decorative properties.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an artificial marble composite panel which is useful as a building material such as floor materials and wall materials. The artificial marble composite panel, which is the object of the present invention, is lightweight, has excellent mechanical strength and water resistance, and is useful in various fields as a building material or the like replacing wood panels.

[0002]

2. Description of the Related Art Conventionally, flooring and wall materials are made of plywood as a core material.
It was used as a building material as a natural marble composite panel by artificially applying an adhesive such as silicon to the plywood and sandwiching it between the natural marble layers. However, the artificial marble composite panel using plywood as a core material has a big problem. The problem is inferior water resistance. When used on outer walls, the adhesive of plywood, which is the core material, deteriorates over time due to water leakage and dew condensation due to rainfall, or high humidity, and the veneers that make up the plywood peel off and lose the strength of the core material. , Is to lose its function as a building material. In particular, with respect to sites and applications where vibrations and stress strains are repeatedly applied, it is not possible to prevent the composite panel from deteriorating with time even by performing thorough construction techniques and daily thorough management. In addition, when joining artificial or natural marble and plywood, the laborious work of applying an adhesive was required. Therefore, plywood, which is a core material, has been conventionally removed and used as a building material such as a floor material and a wall material with a single artificial marble.

However, a single artificial marble is manufactured by curing one resin stone powder mixture layer. According to such a production method, the unsaturated polyester resin layer (hereinafter referred to as a resin layer) mixed in the resin stone powder mixture layer at the time of filling in a mold (not shown) is cured by the resin stone powder mixture layer. In the course of the process, the resin stone powder mixture, which is uncured or semi-cured, is moved upward to its upper surface, and the curing is completed in a state where the resin layer is gathered in the portion forming the surface of the artificial marble composite panel. As a result, the surface of the manufactured artificial marble composite panel after releasing is not smooth due to the shape of the unevenness due to the resin layer, and warp occurs due to the concentration of the resin layer on the surface, which is not preferable in appearance. There was also a problem with stability.

[0004]

SUMMARY OF THE INVENTION The artificial marble composite panel of the present invention has two layers of a primary resin stone powder mixture and a secondary resin stone powder mixture by solving the above-mentioned problems of the prior art. An artificial marble that has a resin layer enclosed in the center, has a smooth surface and does not warp, has a neat appearance suitable for lightweight and excellent building materials, and has excellent mechanical strength and water resistance. It is intended to provide a composite panel.

[0005]

According to the present invention, an artificial marble composite panel is composed of two layers of a primary resin stone powder mixture and a secondary resin stone powder mixture, and an adhesive is used between the two layers. It is in an artificial marble composite panel that is not joined or laminated and integrated. In the present invention, the resin stone powder mixture constituting the artificial marble is a resin composition containing calcium carbonate powder, an unsaturated polyester resin containing a curing accelerator and a curing agent as main components.

[0006]

According to the present invention, when each of the primary and secondary resin stone powder mixture is filled into the mold, the resin layer mixed in each resin stone powder mixture layer is cured to the primary Curing is completed in the state of being enclosed in the vicinity of the interface between the resin stone powder mixture layer and the secondary resin stone powder mixture layer, and an artificial marble composite panel is formed. As a result, it is possible to manufacture an artificial marble composite panel having a flat and smooth surface without unevenness formed by the resin layer on the surface and no warpage.

[0007]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment of the present invention will be described below with reference to FIG. FIG. 1 is a vertical sectional view showing an embodiment of an artificial marble composite panel according to the present invention, which is generally used as a floor material or a wall material. Reference numeral 1 is a primary resin stone powder mixture that constitutes artificial marble, and is a resin composition containing calcium carbonate powder, an unsaturated polyester resin containing a curing accelerator and a curing agent as main components. Reference numeral 2 is a secondary resin stone powder mixture that constitutes artificial marble, and is a resin composition containing calcium carbonate powder, an unsaturated polyester resin containing a curing accelerator and a curing agent as main components, like the primary resin stone powder mixture. It is a thing. The resin stone powder mixture is bonded to each other without using an adhesive, and the resin stone powder mixture is filled in a mold (not shown), a lid plate is placed on the resin stone powder mixture, and the unsaturated polyester resin is applied under pressure. Since it is cured and laminated together, it is possible to manufacture an artificial marble composite panel in which the two layers are extremely firmly bonded to each other.

The method of manufacturing the artificial marble composite panel according to the present invention is as follows. To the mold type, the first resin stone powder mixture 1 was added to the mold type at about 1 / the depth of the mold type.
Fill to a height of 2. The resin stone powder mixture 1 is composed of calcium carbonate powder and an unsaturated polyester resin containing a curing accelerator and a curing agent. Then, the filled primary resin stone powder mixture layer 1 is cured from the bottom, and the upper portion is kept in an uncured or semi-cured state. At this time, the resin layer 3 existing in the primary resin stone powder mixture layer Is moved upward toward the upper surface of the primary resin stone powder mixture layer 1. At this point, the first resin stone powder mixture layer 1 is hardened to about half. Since the resin layer 3 is concentrated on the upper portion of the resin stone powder mixture layer and the calcium carbonate stone powder 4 is concentrated on the lower portion due to the specific gravity, a difference occurs when contracting during curing, and the resin layer has a larger contraction rate. Warpage occurs in a concave shape on the upper side.

Thereafter, the secondary resin stone powder mixture 2 is formed on the primary resin stone powder mixture layer 1 of the mold type.
The height of the mold only a little higher than the depth of the mold.
Fill so that it rises to a level that exceeds the top opening of the rudder shape. The secondary resin stone powder mixture 2 is a resin composition having the same quality as the primary resin stone powder mixture 1. Since the secondary resin stone powder mixture layer is filled on the primary resin stone powder mixture layer in this manner, the resin layer is reduced and warpage is eliminated. In addition, if necessary, the secondary resin stone powder 2 is filled not only once on the primary resin stone powder mixture layer 1 but also a plurality of times, so that the resin layer is further reduced and a high quality artificial marble composite panel is manufactured. can do.

Then, a reinforced plastic lid plate (not shown) having a rectangular flat lower back surface having an area larger than that of the mold type top surface opening is prepared and separated from the lower back surface of the lid plate. After applying the molding agent, a mold type top surface opening filled with the first and second resin stone powder mixtures 1 and 2 is formed.
The lid plate is sealed, and the lower back surface of the lid plate is moped.
The mold type top plate assembly is formed by contacting and pressing the mold type top opening.

Then, before the secondary resin stone powder mixture 2 is completely hardened, the assembly of the mold and the cover plate is inverted. At this time, the resin layer 3 existing in the secondary resin stone powder mixture layer 2 tends to rise toward the primary resin stone powder mixture layer 1. However, the first resin stone powder mixture layer 1
Since most of the resin has already hardened from the top to the bottom, the resin layer 3 together with the resin layer 3 present in the primary resin stone powder mixture layer 1 is a primary resin stone powder mixture layer. 1 and the secondary resin stone powder mixture layer 2 remain near the boundary surface.

Thus, the resin layer 3 present in the secondary resin stone powder mixture layer 2 is raised toward the vicinity of the boundary surface between the primary resin stone powder mixture layer 1 and the secondary resin stone powder mixture layer 2. After moving, the assembly of the mold type and the lid plate in the inverted state is under pressure and uniformly pressed against the lower back surface of the lid plate so as to cover the top surface opening of the mold type,
The mold type and the cover plate assembly are appropriately heated to cure the primary and secondary resin stone powder mixture layers 1 and 2 filled in the mold type. In addition, during this period, a part of the uncured secondary resin stone powder mixture 2 sticks out from the peripheral edge of the mold and is cured.

Thereafter, the cured primary and secondary
The next resin stone powder mixture layers 1 and 2 are released from the mold and the cover plate, and unnecessary portions including the protruding portion are removed. Note that this removal work can be easily performed.
In this way, the artificial marble composite panel is formed in which the resin layer is enclosed and has a smooth surface and has a neat appearance without warpage.

Since the artificial marble composite panel described above is light in weight and excellent in mechanical strength and water resistance,
It can be applied in a wide range and the color and pattern can be freely changed by using additives such as various coloring agents as needed for artificial marble, and buffing can be done as it is. Since the surface is smooth and has a luster, the artificial marble composite panel excellent in decoration can be manufactured.

[0015]

As described above, according to the present invention, the resin stone powder mixture is applied to the artificial marble composite panel forming mold having a predetermined shape two or more times at regular intervals. After the secondary resin stone powder mixture is filled in a divided manner and before the secondary resin stone powder mixture is completely cured, it is sealed with a lid plate in a mold to remove the mold and Since the cover plate assembly is formed, and the assembly is inverted and cured, the resin layer present in the filled resin stone powder mixture layer is the boundary surface of the primary and secondary resin stone powder mixture layers. The resin stone powder mixture layer is hardened in a state of being contained in the vicinity, and an artificial marble composite panel is formed. Therefore, an artificial marble composite panel having a smooth appearance with no unevenness formed by the resin layer and having no warp, excellent mechanical strength and water resistance, and a neat appearance that is also decoratively excellent Utilizing the characteristics, it is useful in various fields as a building material or the like replacing wood panels.

[Brief description of drawings]

FIG. 1 is a vertical sectional view showing an embodiment of an artificial marble composite panel according to the present invention.

[Explanation of symbols]

 1 Primary resin stone powder mixture 2 Secondary resin stone powder mixture 3 Unsaturated polyester resin layer 4 Calcium carbonate stone powder

Claims (1)

[Claims] 1. An artificial marble composite panel, characterized in that two layers of a primary resin stone powder mixture layer and a secondary resin stone powder mixture layer are superposed on each other, pressure-cured and bonded to be laminated and integrated.