JPH08323783A - Production of artificial marble panel - Google Patents

Abstract

PURPOSE: To easily produce products different in dimensional shape by changing the dimension, shape and arrangement of a form member in the production of an artificial marble panel and to make the structure of a mold simple and inexpensive. CONSTITUTION: A form member 2 is combined with a flat lower template 1 to constitute a form 5 and a flat upper template 6 is placed on the form and the upper template 6 and the form 5 are clamped from above and below to form a casting mold. A curable resin compsn. is injected and charged into the casting mold to obtain an artificial marble panel.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing an artificial marble panel used for members such as building interior materials, housing equipment and furniture.

[0002]

2. Description of the Related Art Conventionally, as a method for manufacturing an artificial marble panel, a casting mold comprising an upper mold made of metal or reinforced plastic and a lower mold having a concave cavity is used. A method of injecting a liquid or slurry thermosetting resin composition into a mold to cure the composition.

There has been a method in which a thermosetting resin composition is continuously extruded into a flat plate to be cured, and then cut into a predetermined length.

[0004]

However, metal,
Alternatively, in the method of molding an artificial marble panel using a casting mold composed of an upper mold made of reinforced plastic and a lower mold having a concave cavity, the shape of the cavity of the casting mold is By changing,
Products with different shapes can be obtained, but each time the size and shape of the panel changes, a mold corresponding to that shape must be prepared, which increases the types of molds and increases volume and manufacturing costs. However, a lot of curing space was required in the molding process.

A method of curing a thermosetting resin composition while continuously extruding it into a flat plate shape and then cutting it into a certain length is suitable for mass production of flat plates, but requires high-precision equipment. Since the molded product is limited to a simple flat plate shape, when a product other than a flat plate such as a counter deck is required, secondary processing such as joining and cutting is performed to finish it into a desired shape.

In the present invention, in the manufacture of an artificial marble panel, by changing the size, shape and arrangement of the frame members, it is possible to easily manufacture products having different sizes and shapes, and to improve the structure of the mold. It aims at simplification.

[0007]

According to the present invention, a frame mold is constructed by combining a prismatic frame mold member having a constant thickness on a flat plate-shaped lower mold plate, and a flat plate-shaped mold is formed on the frame mold. By placing the upper mold plate and pressing it from above and below, a casting mold closed by the upper mold plate surface, the frame mold surface, and the lower mold plate surface is formed, and the thermosetting property is applied to the casting mold. A method for manufacturing an artificial marble panel, which comprises injecting and filling a resin composition, which comprises a casting mold formed by a frame mold and a lower mold plate in which an upper mold plate and a prismatic frame mold member are combined. This is characterized in that the frame mold is provided with a resin injection port and an air discharge port.

In the present invention, flat plate materials such as metal plates and reinforced plastics plates are used as the upper mold plate and the lower mold plate. From the viewpoints of durability and uniformity of surface finish, duralumin plate and chrome plate are used. Metal plates such as plated steel plates, stainless steel plates, and chrome-plated stainless steel plates are suitable, and if necessary, use those with a surface finish such as matte finish and gloss finish.

The frame mold for arranging between the upper mold plate and the lower mold plate to form a mold space is a prismatic straight material made of wood material, various plastics, metal materials, etc.
Alternatively, an angle member or the like is used, and these frame mold members are arranged on the lower mold plate so that a desired mold space is formed. Therefore, it is desirable that the frame-shaped member is prepared in advance so that the mold space has a desired size and shape.

When a porous material such as a wood material is used for the prismatic frame member used for the frame mold, it is necessary to improve the releasability by coating or coating with a plastic film, a metal foil or the like.

For injecting and degassing the thermosetting resin composition,
Provide a resin inlet and an air outlet directly on the frame member,
Alternatively, a separately prepared resin injection port and air exhaust port are assembled with a combination frame mold.

Further, depending on the shape of the artificial marble panel, it is possible to arrange the core at a desired position in the frame mold for the purpose of reducing the thickness of the material to save the material and installing an opening.

In constructing the casting mold, after the frame die is assembled on the lower mold plate, the upper mold plate is placed to form a cavity, and the upper mold plate and the lower mold plate are clamped and pressed. Thus, the mold is clamped, and the upper mold plate, the frame mold, and the lower mold plate are tightly fixed to each other to obtain a mold clamping force that withstands the injection pressure of the molding material. The mold clamping can be performed by a tan buckle, a multi-stage or a single-stage flat plate press.

The pressurization by the flat plate press can use a multi-stage press, or a plurality of casting molds can be inserted into the same stage to simultaneously form a plurality of molds.
It can be manufactured efficiently. Further, by using the pressure plate having the heating mechanism, the mold can be heated or cooled to a desired temperature, and the mold temperature can be easily controlled.

It is necessary that the lower die plate and the frame die, or the frame die members or the frame die and the upper die plate are mated with each other so that a step gap is not generated in the die mating portion. Leakage of the thermosetting resin composition injected into the mold can be prevented.

Before the casting, a mold release agent such as wax or silicone resin is applied to the surfaces of the lower mold plate, the frame mold and the upper mold plate, which are the mold surfaces, so that the molded product can be easily separated from the mold. Can be made.

The thermosetting resin composition used in the present invention is a liquid or slurry composition composed of materials such as a liquid thermosetting resin, a filler, a coloring agent and a curing agent, and is cast. After being filled in a mold, it is cured.

The thermosetting resin composition used in the present invention is an unsaturated polyester resin, an unsaturated melamine resin, a vinyl ester resin, a methylmethacryl resin, etc.,
Fillers include powders of calcium carbonate, aluminum hydroxide, silica, etc., hardened resin particles, crushed stone particles, etc. These materials have the appearance required for artificial marble,
It is appropriately blended so as to obtain physical properties.

The compounded thermosetting resin composition is injected into the casting mold through the resin injection port and then degassed, followed by heating at room temperature or a relatively low temperature to cure and decompress. Remove the mold. The molded product thus obtained is, if necessary, heat-cured in a curing room to proceed with after-cure to obtain an artificial marble panel.

[0020]

EXAMPLES Parts and% shown below represent parts by weight and% by weight, respectively. Example 1 A 5 mm thick matte finish chrome-plated stainless steel plate was used as the lower template 1, and a thickness 1 made of polyester resin was used.
A frame-shaped member 2 composed of straight and angled prisms having a square section of 8 mm is arranged at a predetermined position so as to provide a resin inlet 3, and an air outlet 4, and a frame 5 is assembled. Then, the upper mold plate 6 having the same specifications as the lower mold plate was placed to form a casting mold 7.

The portions of the upper mold plate 1, the frame mold 5, and the lower mold plate 6 of the casting mold 7 which are to be the mold surfaces are thinly coated with a silicone resin wax as a mold release agent prior to the construction of the mold. It was applied uniformly.

Next, the casting mold 7 is inserted between the pressure plates 8 of the vertical die flat plate press machine so that the resin injection port 3 and the air discharge port 4 are on the upper side, and the pressure of 3 Kgf / cm ² is applied. Then, the casting mold 7 was hermetically fixed to form a cavity 8.
The pressure plate 9 of this flat plate press has a structure capable of heating and cooling by circulating hot water or cold water as a heat medium.

The thermosetting resin composition 10 to be injected into the casting mold 7 has the following material composition: 100 parts of isophthalic acid type unsaturated polyester resin, average particle diameter 30 μm.
200 parts of aluminum hydroxide, 5 parts of glass fiber chop strands having a fiber length of 1.5 mm, 0.4 parts of Percadox 16 (made by Kayaku Akzo) and 0.6 parts of Trigonox 121 (made by Kayaku Akzo) as a curing agent. Each is a slurry-like material having a material temperature of 35 ° C., which was obtained by agitating for 30 minutes under a sealed vacuum with a hot water jacket.

This thermosetting resin composition 10 is injected into the cavity 8 from the resin injection port 3 of the casting mold 7 described above and filled while being replaced with air, and the mold temperature is kept at 80 ° C. for 60 minutes. Then, after curing the thermosetting resin composition 10, 30
Cool down to ℃, decompress, demold, finish the end face,
An artificial marble panel for a counter top plate was obtained.

[0025]

According to the present invention, a casting mold for molding an artificial marble panel can be easily constructed by combining the upper mold plate, the frame mold and the lower mold plate and pressing them. Since the volume is not large, the mold can be economically manufactured. Also, by changing the arrangement and shape of the frame mold and arranging the core in the mold, it becomes possible to easily form panels having different shapes and dimensions.

Further, in flat plate press or tanbuckle pressing, a plurality of casting molds can be inserted and arranged between the pressing plates, so that the productivity is good and the mass production is suitable.

[0027]

[Brief description of drawings]

FIG. 1 is a perspective view showing an example of the structure of a casting mold used in the present invention, and AA ′ shows the position of the cross section of FIGS. 2 and 3. FIG.

FIG. 2 is a sectional view showing an example of the structure of a casting mold used in the present invention.

FIG. 3 is a sectional view showing an example of a state where a thermosetting resin composition is injected and filled in a casting mold according to the present invention.

[Explanation of symbols]

 1 Lower Mold Plate 2 Frame Mold Member 3 Resin Injection Port 4 Air Discharge Port 5 Frame Mold 6 Upper Mold Plate 7 Cast Mold 8 Cavity 9 Pressurizing Plate 10 Thermosetting Resin Composition

Claims (2)

[Claims] 1. A frame-shaped die is formed by combining prismatic frame-shaped members having a constant thickness on a flat plate-shaped lower mold plate, and the flat plate-shaped upper mold plate is placed on the frame mold. Forming a casting mold closed by the upper mold plate surface, the frame mold surface, and the lower mold plate surface by pressing from above and below, and injecting and filling the thermosetting resin composition into the casting mold. A method for manufacturing an artificial marble panel, which is characterized by: 2. A resin mold inlet and an air outlet are provided in a frame die formed by combining an upper die plate and a prismatic frame die member, and a frame die of a casting mold formed by a lower die plate. The method for manufacturing an artificial marble panel according to claim 1, wherein: