JPH1199592A - Artificial marble and its production - Google Patents
Artificial marble and its productionInfo
- Publication number
- JPH1199592A JPH1199592A JP26335997A JP26335997A JPH1199592A JP H1199592 A JPH1199592 A JP H1199592A JP 26335997 A JP26335997 A JP 26335997A JP 26335997 A JP26335997 A JP 26335997A JP H1199592 A JPH1199592 A JP H1199592A
- Authority
- JP
- Japan
- Prior art keywords
- artificial marble
- mold
- raw material
- marble according
- granular raw
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
Links
- 239000002928 artificial marble Substances 0.000 title claims abstract description 34
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 17
- 239000002994 raw material Substances 0.000 claims abstract description 34
- 229920005989 resin Polymers 0.000 claims abstract description 27
- 239000011347 resin Substances 0.000 claims abstract description 27
- 239000000203 mixture Substances 0.000 claims abstract description 20
- 239000000463 material Substances 0.000 claims description 28
- 238000005266 casting Methods 0.000 claims description 8
- 239000011362 coarse particle Substances 0.000 claims description 7
- 238000005507 spraying Methods 0.000 claims description 7
- 239000002245 particle Substances 0.000 claims description 4
- 239000000843 powder Substances 0.000 claims description 4
- 239000008187 granular material Substances 0.000 claims description 3
- 239000000758 substrate Substances 0.000 claims 3
- 238000010438 heat treatment Methods 0.000 claims 1
- 239000004575 stone Substances 0.000 abstract description 6
- 238000000034 method Methods 0.000 abstract description 4
- 239000000853 adhesive Substances 0.000 abstract description 2
- 230000001070 adhesive effect Effects 0.000 abstract description 2
- 239000000470 constituent Substances 0.000 abstract 1
- 239000010410 layer Substances 0.000 description 13
- 239000007921 spray Substances 0.000 description 6
- 238000000465 moulding Methods 0.000 description 4
- 239000003795 chemical substances by application Substances 0.000 description 3
- 238000010586 diagram Methods 0.000 description 3
- 229920006337 unsaturated polyester resin Polymers 0.000 description 3
- 239000002131 composite material Substances 0.000 description 2
- 150000001875 compounds Chemical class 0.000 description 2
- 239000011159 matrix material Substances 0.000 description 2
- 238000010422 painting Methods 0.000 description 2
- 239000000049 pigment Substances 0.000 description 2
- 238000004062 sedimentation Methods 0.000 description 2
- 239000002344 surface layer Substances 0.000 description 2
- WFUGQJXVXHBTEM-UHFFFAOYSA-N 2-hydroperoxy-2-(2-hydroperoxybutan-2-ylperoxy)butane Chemical compound CCC(C)(OO)OOC(C)(CC)OO WFUGQJXVXHBTEM-UHFFFAOYSA-N 0.000 description 1
- 239000004923 Acrylic lacquer Substances 0.000 description 1
- 239000003054 catalyst Substances 0.000 description 1
- 238000011109 contamination Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 229920001971 elastomer Polymers 0.000 description 1
- 238000009415 formwork Methods 0.000 description 1
- 230000005484 gravity Effects 0.000 description 1
- 230000000977 initiatory effect Effects 0.000 description 1
- 239000004579 marble Substances 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 210000004761 scalp Anatomy 0.000 description 1
- 229920002803 thermoplastic polyurethane Polymers 0.000 description 1
- 238000002834 transmittance Methods 0.000 description 1
Landscapes
- Laminated Bodies (AREA)
- Compositions Of Macromolecular Compounds (AREA)
Abstract
Description
【０００１】[0001]
【発明の属する技術分野】本発明は、人工大理石および
その製造方法に関し、特に、粒状原料を含む人工大理石
に関する。BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to artificial marble and a method for producing the same, and more particularly, to artificial marble containing granular raw materials.
【０００２】[0002]
【従来の技術】石目調の人工大理石を製造するにあたっ
ては、マトリックス樹脂および粉体原料の混合物と、石
目を表現する有色の粒状原料とを混ぜ合わせ、これを図
１に示すように任意の形状を有する型枠２に成形した
後、硬化，脱型し、図２に示すような人工大理石４を成
形する方法が一般的に広く行われている。2. Description of the Related Art In producing a stone-grain artificial marble, a mixture of a matrix resin and a powder raw material is mixed with a colored granular raw material that expresses a stone, and this is optionally mixed as shown in FIG. In general, a method of forming an artificial marble 4 as shown in FIG.
【０００３】このような成形品では、粒状原料が高価な
場合は成形品も高価になり、比重が高い場合には成形品
の重量が重くなり、材料に強度がない場合には厚みを厚
くしても成形品が必要な強度を保持し得ないので、図３
に示すように、粒状原料を含む樹脂成形品６を表装材と
して設け（厚み数〜１０ｍｍ）、さらに異なる組成の樹
脂よりなる裏打材８を接着一体化せしめた石目調複合成
形体１０も考案されている（特開平８−１５７２４８号
公報および特開平９−１７６６号公報参照）。In such a molded article, when the granular raw material is expensive, the molded article is also expensive, when the specific gravity is high, the weight of the molded article is heavy, and when the material has no strength, the thickness is increased. Even though the molded product cannot maintain the required strength, FIG.
As shown in Fig. 7, a resin-grained composite molded product 10 in which a resin molded product 6 containing a granular raw material is provided as a surface covering material (thickness: 10 mm) and a backing material 8 made of a resin having a different composition is integrally bonded is also devised. (See JP-A-8-157248 and JP-A-9-1766).
【０００４】[0004]
【発明が解決しようとする課題】表装材に裏打材を接着
一体化せしめた人工大理石は、次のような問題がある。 （１）価格が高い。その理由は、概して有色の粒状原料
は単価が高く、加えて外観上、製品表面（化粧面）に粒
状原料を出現させ、かつ裏打材をも遮るためには相当量
の混入が必要となり、コストアップとなるからである。The artificial marble in which a backing material is integrally bonded to a surface material has the following problems. (1) The price is high. The reason is that colored granular raw materials generally have a high unit price, and in addition, in order to make the granular raw materials appear on the product surface (decorative surface) and also to block the backing material, a considerable amount of mixing is necessary, and the cost is high. Because it will be up.
【０００５】また、マトリックス樹脂に顔料を混入した
場合は透過度が低下するため、石目模様を表現するには
粒状原料をさらに大量添加する必要があるからである。 （２）変形しやすい。その理由は、表装材と裏打材との
間に収縮差が、成形時あるいは成形後の温度や湿度変化
等により生じた場合、反りが発生しやすいからである。
また、このような反りが発生すると、表装材と裏打材と
が剥離する危険性もある。 （３）製品部位で色調が異なることがある。その理由
は、表装材の厚みが大きい場合、表装材の成形時に型枠
の水平部と垂直部における粒状原料の沈降速度の影響か
ら石目の濃淡が生じやすくなるからである。 （４）工数が増加する。その理由は、表装材の成形のた
め、プレス成形や注型，脱型等の数工程が必要となるか
らである。Further, when a pigment is mixed into the matrix resin, the transmittance is reduced, so that it is necessary to add a large amount of granular raw material to express a stone pattern. (2) easy to deform; The reason for this is that when a difference in shrinkage between the facing material and the backing material occurs due to a change in temperature or humidity during or after molding, warpage tends to occur.
Further, when such a warp occurs, there is a risk that the facing material and the backing material may peel off. (3) The color tone may differ depending on the product part. The reason is that, when the thickness of the facing material is large, shading tends to occur due to the influence of the sedimentation speed of the granular raw material in the horizontal part and the vertical part of the form during molding of the facing material. (4) Man-hours increase. The reason is that several steps such as press molding, casting, and demolding are required for molding the surface covering material.
【０００６】本発明の目的は、粒状原料を表層（化粧
層）のみに配する一体物であって、石目の色調を制御し
た人工大理石およびその製造方法を提供することにあ
る。An object of the present invention is to provide an artificial marble in which the granular raw material is arranged only on the surface layer (decorative layer), in which the color tone of the grain is controlled, and a method for producing the same.
【０００７】[0007]
【課題を解決するための手段】本発明の人工大理石は、
粉体原料を含む基材と、基材上の化粧層とよりなり、化
粧層にのみ粒状原料を含んでいる。The artificial marble of the present invention comprises:
It consists of a base material containing a powdery raw material and a decorative layer on the base material, and only the decorative layer contains the granular raw material.
【０００８】このような人工大理石を製造するには、ま
ず、粒状原料と透明樹脂の混合物を、型枠表面に、密度
が概ね均一にかつ型枠表面の地肌を残すように吹き付け
る。粒状原料は、透明樹脂をその接着剤として、型枠表
面に付着する。その後、製品の基材として注型層を設
け、脱型を経て石目調成形品を得る。In order to produce such an artificial marble, first, a mixture of a granular raw material and a transparent resin is sprayed on the surface of a mold so that the density is substantially uniform and the background of the surface of the mold is left. The granular raw material adheres to the surface of the mold using the transparent resin as an adhesive. Thereafter, a casting layer is provided as a base material of the product, and a stone-like molded product is obtained through demolding.
【０００９】[0009]
【発明の実施の形態】図面を参照して、本発明の実施の
形態を説明する。Embodiments of the present invention will be described with reference to the drawings.
【００１０】図４〜図６は、人工大理石の製造の各工程
を示す図である。FIG. 4 to FIG. 6 are diagrams showing each step of the production of artificial marble.
【００１１】（１）まず、石目を表現するための粒状原
料と透明な樹脂とを含む混合物１１の配合を調整する。(1) First, the composition of a mixture 11 containing a granular raw material for expressing stones and a transparent resin is adjusted.
【００１２】粒状原料は、粒度が０．３〜３．０ｍｍの
粗粒よりなり、透明樹脂と粒状原料との重量比は、１０
０：４０〜２００とした。この粒度の粗粒を、この重量
比で混合することにより、型枠表面に均一に吹き付ける
ことができる。この重量比以下では粗粒が分散しにく
く、以上では粗粒が型枠表面に付着しにくい。The granular material is composed of coarse particles having a particle size of 0.3 to 3.0 mm, and the weight ratio of the transparent resin to the granular material is 10%.
0: 40 to 200. By mixing coarse particles of this particle size at this weight ratio, it is possible to spray uniformly on the surface of the mold. Below this weight ratio, the coarse particles are difficult to disperse, and above this, the coarse particles are less likely to adhere to the mold surface.
【００１３】（２）上記混合物１１を、図４に示すよう
に、人工大理石の注型のための型枠２の表面に、建築塗
装用スプレーガン１２で均一に吹き付ける。この時、型
表面の粒状原料の混合物は膜を形成しない分散した状態
であり、石目調の濃淡に応じて吹付密度を低〜高密度
（２０〜２００ｇ／ｍ2 ）まで調整することができる。(2) As shown in FIG. 4, the mixture 11 is uniformly sprayed on the surface of the mold 2 for casting artificial marble by a spray gun 12 for building painting. At this time, the mixture of the granular raw materials on the mold surface is in a dispersed state that does not form a film, and the spray density can be adjusted from low to high (20 to 200 g / m 2 ) according to the density of the grain. .
【００１４】この混合物が硬化する前に以下の（３）の
工程に進むことができる。Before the mixture is cured, the process can proceed to the following step (3).
【００１５】なお、混合物を吹き付ける前に、型枠２の
表面に予めゲルコートを塗布しておくこともできる。Before the mixture is sprayed, a gel coat may be applied to the surface of the mold 2 in advance.
【００１６】ゲルコートとは型枠表面に塗布する概ね
０．１〜０．５ｍｍ厚の樹脂層のことで、これにより製
品の耐久性，耐汚染性を高めることができる。この樹脂
には通常、不飽和ポリエステル樹脂を用いる。透明樹脂
と粒状原料の混合物を吹き付ける前に、少なくとも流動
性が無くなる程度に硬化させるのが望ましい。The gel coat is a resin layer having a thickness of about 0.1 to 0.5 mm applied to the surface of the mold, and can improve the durability and stain resistance of the product. Generally, an unsaturated polyester resin is used for this resin. Before spraying the mixture of the transparent resin and the granular raw material, it is desirable to cure at least to such an extent that the fluidity is lost.
【００１７】（３）全面に任意の色調をもつ粉体原料を
含む基材１４を、図５に示すように、５〜２０ｍｍの厚
みでバックレジン層として注型する。(3) A base material 14 containing a powder material having an arbitrary color tone over the entire surface is cast as a back resin layer with a thickness of 5 to 20 mm as shown in FIG.
【００１８】（４）バックレジン層を硬化させ、型枠か
ら脱型すると、図６に示すように、表面に石目調の模様
をもつ製品が得られる。なお、上記（２）の工程でゲル
コートを設けてない場合、製品の表面の汚れ防止、保護
の点から透明樹脂のトップコートを施しても良い。(4) When the back resin layer is cured and released from the mold, a product having a stone-like pattern on the surface is obtained as shown in FIG. When the gel coat is not provided in the step (2), a top coat of a transparent resin may be applied from the viewpoint of preventing contamination of the surface of the product and protecting the product.
【００１９】トップコートとは製品脱型後に製品表面に
塗装を行う工法であり、ラッカー系，ポリエステル系，
ウレタン系，ＵＶ系等の樹脂を要求性能に合わせて使
う。The top coat is a method of painting the product surface after the product is released from the mold.
Use urethane resin, UV resin, etc. according to the required performance.
【００２０】[0020]
【実施例１】 （１）混合物として、表１の配合表の通り、透明樹脂
と、粒状原料の粗粒と、硬化剤とを混合する。Example 1 (1) As a mixture, a transparent resin, coarse particles of a granular raw material, and a curing agent are mixed as shown in the composition table of Table 1.
【００２１】[0021]
【表１】 [Table 1]
【００２２】（２）上記混合物を型枠の製品表面側にス
タッコガンを用いて、吹付け圧：５ｋｇｆ／ｃｍ2 、吹
付け密度：２０〜２００ｇ／ｍ2 （但し、飛散量を除
く）で吹き付ける。吹付け密度が２０ｇ／ｍ2 より低い
と、大理石としての高級感に欠け、２００ｇ／ｍ2 より
高くなると、型枠表面の地肌が残らなくなる。(2) The above mixture is sprayed on the product surface side of the mold using a stucco gun at a spray pressure of 5 kgf / cm 2 and a spray density of 20 to 200 g / m 2 (excluding the amount of scattering). . When spraying density is less than 20 g / m 2, lacking in luxury as marble, becomes higher than 200 g / m 2, it does not remain the scalp mold surface.
【００２３】（３）他方、バックレジン層のコンパウン
ドとして表２の配合表の通り、透明樹脂と、粉体と、ト
ーナーと、硬化剤とを混合する。(3) On the other hand, as a compound of the back resin layer, a transparent resin, a powder, a toner, and a curing agent are mixed as shown in the composition table of Table 2.
【００２４】トーナーは顔料を５０％前後の展色剤に分
散懸濁させたペースト状のもので、バックレジン層の色
調整のため０．１〜３．０部添加される。金属および有
機系のトーナーがあり、樹脂の硬化時，硬化後の特性に
影響することがあるので、不飽和ポリエステル樹脂専用
のトーナーを用いるのが好ましい。The toner is a paste in which a pigment is dispersed and suspended in about 50% of a vehicle, and 0.1 to 3.0 parts is added for adjusting the color of the back resin layer. Since there are metal and organic toners, which may affect the properties of the resin during and after curing, it is preferable to use a toner dedicated to the unsaturated polyester resin.
【００２５】硬化剤とは、不飽和ポリエステル樹脂の硬
化反応を開始せしめるための触媒で、通常メチルエチル
ケトンパーオキシドの溶液が用いられる。The curing agent is a catalyst for initiating the curing reaction of the unsaturated polyester resin, and usually a solution of methyl ethyl ketone peroxide is used.
【００２６】[0026]
【表２】 [Table 2]
【００２７】（４）上記コンパウンドを型枠上に約１０
ｍｍの厚みで注型する。注型量は、約１３ｋｇ／ｍ2 で
あった。(4) Place the above compound on a mold for about 10
Cast with a thickness of mm. The casting rate was about 13 kg / m 2 .
【００２８】（５）型枠全体を４０〜６０℃のキュア室
で１〜２時間加温して製品を硬化せしめ、脱型して、人
工大理石を得る。(5) The entire mold is heated in a cure room at 40 to 60 ° C. for 1 to 2 hours to cure the product, and the mold is removed to obtain an artificial marble.
【００２９】（６）製品表面に透明アクリルラッカーを
１００〜２００ｇ／ｍ2 塗布する。(6) 100 to 200 g / m 2 of a transparent acrylic lacquer is applied to the product surface.
【００３０】[0030]
【実施例２】実施例１では型枠の表面はフラットである
が、型枠表面に凹凸のテキスチャーがあっても良い。特
に凹凸形状のある時の型枠は表面硬度の低い、ゴム型な
どを用いることもできる。この凹凸形状を備えることに
より、天然石の表面のテキスチャーに近づけることがで
きる。Second Embodiment In the first embodiment, the surface of the mold is flat, but the surface of the mold may have an uneven texture. In particular, a rubber mold or the like having a low surface hardness can be used as a mold frame having an uneven shape. By providing this uneven shape, it is possible to approach the texture of the surface of the natural stone.
【００３１】[0031]
【実施例３】バックレジン層は、粒状原料の吹き付け
後、裏型を設けてその隙間に注型で成形しても良い。ま
た、粒状原料吹き付け後に、バックレジン層を吹き付け
で形成しても良い。Embodiment 3 After the granular raw material is sprayed, the back resin layer may be formed by providing a back mold and casting the gap between the back molds. After the granular raw material is sprayed, the back resin layer may be formed by spraying.
【００３２】[0032]
【発明の効果】本発明によれば、以下の効果が得られ
る。According to the present invention, the following effects can be obtained.
【００３３】（１）高価な粒状原料は製品表層にのみ配
置されるため、従来の注型層混入と比較してその使用量
には際だった少量化が可能となる。その結果、コストダ
ウンを図ることができる。(1) Since the expensive granular raw material is disposed only on the surface layer of the product, the amount of the raw material used can be remarkably reduced as compared with the conventional casting layer mixing. As a result, cost can be reduced.
【００３４】（２）製品の基材注型層の配合には粒径の
大きな原料は含まれないので、強度が著しく低下するこ
とはなく、強度を保持することができる。(2) Since the raw material having a large particle size is not included in the composition of the base material casting layer of the product, the strength is not remarkably reduced and the strength can be maintained.
【００３５】（３）予め粒状原料を型枠の表面に吹き付
けるので、粗粒の沈降の影響を受けにくい。その結果、
製品部位で色調が一様となる。(3) Since the granular raw material is sprayed on the surface of the mold in advance, it is hardly affected by sedimentation of coarse particles. as a result,
The color tone becomes uniform at the product site.
【００３６】（４）裏打材を用いないので、粒状原料の
型枠表面への吹付けの一工程を従来工程に組み込むだけ
で済む。(4) Since no backing material is used, it is only necessary to incorporate one step of spraying the granular raw material onto the surface of the mold into the conventional step.
【図１】従来の製造方法を示す図である。FIG. 1 is a diagram showing a conventional manufacturing method.
【図２】従来の製造方法により製造された人工大理石を
示す図である。FIG. 2 is a view showing an artificial marble manufactured by a conventional manufacturing method.
【図３】表装材と裏打材とを接着一体化した人工大理石
を示す図である。FIG. 3 is a view showing an artificial marble in which a facing material and a backing material are bonded and integrated.
【図４】本発明の人工大理石の製造方法を示す図であ
る。FIG. 4 is a diagram showing a method for producing artificial marble of the present invention.
【図５】本発明の人工大理石の製造方法を示す図であ
る。FIG. 5 is a view showing a method for producing an artificial marble of the present invention.
【図６】本発明の人工大理石を示す図である。FIG. 6 is a view showing an artificial marble of the present invention.
２ 型枠 ４ 人工大理石 ６ 表装材 ８ 裏打材 １０ 複合成形体 １１ 混合物 １２ スプレーガン １４ 基材 2 Formwork 4 Artificial marble 6 Surface material 8 Backing material 10 Composite molded body 11 Mixture 12 Spray gun 14 Base material
Claims (13)
よりなり、化粧層にのみ粒状原料を含むことを特徴とす
る人工大理石。1. An artificial marble comprising a substrate containing a powder material and a decorative layer on the substrate, wherein only the decorative layer contains a granular material.
ｍの粗粒よりなることを特徴とする請求項１記載の人工
大理石。2. The granular raw material has a particle size of 0.3 to 3.0 m.
2. The artificial marble according to claim 1, wherein the artificial marble comprises coarse particles of m.
り、透明樹脂と粒状原料との重量比は、１００：４０〜
２００であることを特徴とする請求項２記載の人工大理
石。3. The granular raw material is mixed with a transparent resin, and the weight ratio of the transparent resin to the granular raw material is from 100: 40 to
The artificial marble according to claim 2, wherein the number is 200.
２０〜２００ｇ設けられていることを特徴とする請求項
３記載の人工大理石。4. The artificial marble according to claim 3, wherein the mixture is provided in an amount of 20 to 200 g per 1 m 2 on the substrate.
ることを特徴とする請求項１〜４のいずれかに記載の人
工大理石。5. The artificial marble according to claim 1, wherein a top coat is applied to the surface of the decorative layer.
枠表面に、密度が概ね均一にかつ型枠表面の地肌を残す
ように吹き付ける工程と、 続いて前記型枠内に基材を設ける工程と、 成形体を型枠から脱型する工程と、を含むことを特徴と
する人工大理石の製造方法。6. A step of spraying a mixture containing a granular raw material and a transparent resin on the surface of the mold so that the density is substantially uniform and the background of the surface of the mold is left. A method for producing artificial marble, comprising a step of providing and a step of removing a molded body from a mold.
とする請求項６記載の人工大理石の製造方法。7. The method for producing artificial marble according to claim 6, wherein said base material is provided by casting.
特徴とする請求項６記載の人工大理石の製造方法。8. The method for producing artificial marble according to claim 6, wherein said base material is provided by spraying.
ゲルコートを塗布する工程を含むことを特徴とする請求
項６〜８のいずれかに記載の人工大理石の製造方法。9. The method for producing artificial marble according to claim 6, further comprising a step of applying a gel coat to the surface of the mold before spraying the mixture.
る工程を含むことを特徴とする請求項６〜９のいずれか
に記載の人工大理石の製造方法。10. The method for producing artificial marble according to claim 6, further comprising a step of heating the whole before said step of demolding.
トップコートを施す工程を含むことを特徴とする請求項
６，７，８または１０記載の人工大理石の製造方法。11. The method for producing artificial marble according to claim 6, further comprising a step of applying a top coat to the surface of the decorative layer after the step of removing the mold.
特徴とする請求項６〜１１のいずれかに記載の人工大理
石の製造方法。12. The method for producing artificial marble according to claim 6, wherein the surface of the mold is flat.
あることを特徴とする請求項６〜１１のいずれかに記載
の人工大理石の製造方法。13. The method for producing artificial marble according to claim 6, wherein the surface of the mold has an uneven texture.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP26335997A JPH1199592A (en) | 1997-09-29 | 1997-09-29 | Artificial marble and its production |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP26335997A JPH1199592A (en) | 1997-09-29 | 1997-09-29 | Artificial marble and its production |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| JPH1199592A true JPH1199592A (en) | 1999-04-13 |
Family
ID=17388399
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP26335997A Pending JPH1199592A (en) | 1997-09-29 | 1997-09-29 | Artificial marble and its production |
Country Status (1)
| Country | Link |
|---|---|
| JP (1) | JPH1199592A (en) |
-
1997
- 1997-09-29 JP JP26335997A patent/JPH1199592A/en active Pending
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