JPS61143133A - Resin concrete molded shape having stone-like pattern and manufacture thereof - Google Patents

Abstract

(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

DETAILED DESCRIPTION OF THE INVENTION (Industrial Application Field) The present invention is directed to resin concrete C having a stone-like pattern.
This paper relates to the improvement of products (abbreviated as "resicons") and new manufacturing methods.

(Prior Art) Conventionally, so-called resin molded products in which synthetic resin is used as a binder for concrete have been widely used in various fields. Examples of such resin molded products include various flyer tiles, building blocks, and sinks for home gardening, which are made by pouring or hot press molding a mixture of granular aggregate and thermosetting resin. Manufactured. By selecting granular aggregates, so-called polished molded products that resemble marble or granite were also developed and became popular in nine markets.

(Problems to be Solved by the Invention) However, the above-mentioned resin molded products can be made by mixing various types of granular aggregate at the same time to form a so-called marble pattern, or by using a single type of aggregate to form a uniform pattern. It was virtually impossible to obtain flowing patterns and other varied patterns like natural stone.

In addition, it is often made rich in bonding resin because gloss and shine are valued, and the entire molded product is made of such resin, which makes it expensive (because the price of bonding resin accounts for a large proportion). It was undeniable that this would happen. Furthermore, due to the characteristics of the manufacturing method, the shapes are limited to relatively simple shapes or those made by Asaya, and the lack of variety and price disadvantages of conventional molded products make it difficult to meet the diverse needs of users. was insufficient, and drastic improvements were desired.

Means for Solving Problem C) The present invention has been made in view of the above, and is a novel stone that has various stone-like patterns like natural stone, can be supplied at low cost, and can also be made into various shapes. The aim is to provide plastic molded products and at the same time propose an effective manufacturing method.

To further explain the present invention in detail based on the accompanying drawings, FIGS. 1(A) and 2(B) are partial longitudinal sectional views of the molded product of the present invention, and FIG. 2 is a schematic process diagram of the method of the present invention. (b) H is a schematic vertical sectional view showing various molds used in the method of the present invention and their molding procedure. That is, 1. The gist of the specific invention of the present invention is that the surface layer portion 5 of resin concrete is formed by bonding natural or artificial granular aggregate X i -... and a large amount of transparent thermosetting resin binder group 2; A resin concrete molded product having a stone-like pattern, characterized in that a base layer part 2 of resin concrete or FRP containing a large amount of filler is laminated together, and the surface of the surface layer part 5 is a smooth surface. The gist of the second invention is a step (I) of mixing natural or artificial granular aggregate l1... with a large amount of transparent thermosetting resin liquid (monomer) 120, and the step Step (II) of spraying and applying the mixture 50 obtained in (I) on the inner surface of the hood frame F and curing it to form a surface layer 5 of resin concrete, and the mold to which the surface layer 5 is fixed. Inject resin concrete raw material 20 containing a large amount of aggregate and filler prepared separately into frame F [Step (■)]
Or, the base layer part 2 is integrated with the surface layer part 5 by coating and curing the FRP raw material 200 on the back surface of the surface layer part 5.
A process for forming a resin concrete molded product having a characteristic stone-like pattern.

(Function) The present invention will be described in more detail along with its function. Second for convenience
First, the manufacturing method of the invention will be explained.

In step (I), the single granular aggregate 11... is made of Kansui stone.

Particle size 0.00 mm obtained by crushing natural stones such as limestone, marble, and Hanazonite. 5-3. Oj! The most preferable are lump-like or flat-shaped granules in No. 11, and chip-like granules obtained by crushing hard colored plastics. Furthermore, a combination of these particles having a particle size within the above range may also be employed. In addition, polyester resin, acrylic resin, or the like is preferably used as the transparent thermosetting resin liquid 520 for bonding the aggregates together. The blending ratio of the aggregate (X
It is appropriate to have 35 to 90 parts by weight of the resin liquid (solid content), and if the amount of the resin liquid exceeds this range, the strength of the resin molded product will tend to decrease. If this happens, the sense of depth, which will be described later, tends to become poor. In this step (I), in addition to these main materials, calcium carbonate, aluminum hydroxide, fillers with weak coloring power such as mica, cobalt octenoate,
A curing accelerator such as cobalt naphthenate, etc. - Methyl ethyl ketone peroxide or the like is appropriately added as a curing agent.

Furthermore, the spraying described later will affect workability during molding (flow, sagging, etc.)
Considering this, solvents and regulators are also added to make the mixture high viscosity (15 to 30 poise) and high thixotropy (3 to 6).
However, it is also possible to adjust the resin liquid).

The thus prepared mixed sea urchin 〇 is sprayed and fixed in various warm frames F in step (If), and a device S with a nozzle diameter of about 3 mm is used for the spraying.

Spraying pressure 1~5Kg/cIIt2 Thickness 0.5~3f
f K is painted. Formwork F...any mold, plastic mold, wooden mold, silicone rubber mold, etc. can be used for the binding.Also, its shape can be a flat type for panels or a three-dimensional type (as shown in Fig. 3). Split mold) F2. Undercut) W (wari fjJL) Fa and various other types of complex shapes for exterior use are used. In order to spray the mixed sea urchin 〇 on the inner surface of this mold F, in the case of a three-dimensional WF2 or an undercut type F3, it is sprayed on the inner surface of each divided piece of porcelain material, and then assembled. Then, the formwork F is placed in a baking furnace (not shown) together with the painted mixed sea urchin 0, and the mixed sea urchin 0 is hardened to combine with the granular aggregates X i --... and the transparent thermosetting resin binder 12. A surface layer part 5 of the resin resin is obtained, in which the and are integrally bonded to each other.

Next, in step (I[I), a base layer part 2 is formed on the back surface of the surface layer part 5, and two methods are adopted for forming this base layer part 2. That is, the first method is a method in which the resin raw material 20 is injected into the frame F.
], the second method is a method of applying FRP raw material 200 [step (mr). In the former case.

This method is used when the formwork F is deep and it is desired to obtain a heavy panel, while in the latter case, it is used when the formwork F is shallow and it is desired to obtain a lightweight panel. also.

Since the resin raw material 20 does not require cosmetic properties different from those required for forming the first surface layer 5, the amount of resin can be reduced and the amount of aggregate or filler can be increased. For example, the mixing ratio is 145 aggregate - 45 filler. Resin: 10 (all parts by weight)
In this case, the ordinary resin construction specifications for civil engineering and construction are adopted as they are, and since the aggregate can be used as gravel for civil engineering, the surface layer can be obtained at a lower cost. On the other hand, a normal FRP raw material 200 is used, and glass fiber and polyester resin are applied to the back surface of the surface layer l by simultaneous spraying. Both raw materials injected or applied in this manner are cured to form the base layer portion 2 which is integrally laminated with the surface layer portion 5.

Then, by demolding the above-mentioned formwork F, a Nariya product can be obtained [Step ■].

The product obtained in this way is explained in Fig. 1 (a) and (b). In the molded product A1 in Fig. 1 U), the base layer part 2 is a resin layer, Fig. 1 The base layer part 2 of Wataru's molded product A2 is FR.
Each indicates that it is a P layer. As clarified by the above-mentioned manufacturing method, in the surface layer 5, the granular aggregates 15... are mutually bonded by a large amount of transparent thermosetting resin binder group 2, so that the aggregates 11-... The random arrangement and the optical properties of the binder 12 combine to create a deep and unique stone-like pattern.

In particular, since a large amount of binder 12 is mixed, a transparent resin layer is reliably formed on the surface, and the deep stone-like pattern is further emphasized. Moreover, this aggregate 111...we have prepared a large number of bound natural aggregates and artificial colored aggregates.

By combining these, various patterns will appear.

Furthermore, since the surface layer 1 is formed by spraying as described above, a plurality of types of mixed sea urchins 0 containing different types of aggregates 15 are prepared, and these are placed separately in the same loading frame F. By dividing the color into stripes, it is possible to arbitrarily express so-called flowing patterns, block patterns, etc. The surface layer is integrated with the base layer 2, and since the base layer 2 does not affect the appearance, it can be used in ordinary civil engineering buildings containing a large amount of aggregate and filler as long as the strength does not decrease. Plastics, FRP, etc. will be used, and molded products can be manufactured at low cost. also.

Conventional plastic molded products can only be obtained by injection molding or press molding, so only relatively simple shapes can be obtained.However, in the molded product of the present invention, the surface layer 5 is formed by spraying. Because of this, various types of formwork F... can be used, and its uses range from normal temperature flannel to complex-shaped Fsteria products.

(Example) Examples will be described below. The surface layer forming mixture used in each example was prepared with the following formulation.

(If) Transparent thermosetting resin repair 30 [
Unsaturated polyester resin] (Il+) filler; [calcium carbonate] 300% reinforcing material; [glass fiber] 2 total 5
〇〇The inner surface was sprayed to a thickness of 2πM, and the formwork was assembled and hardened in a baking oven.

(b) A resin resin material for the base layer was prepared with the following formulation.

(ll) Filler; [calcium carbonate] 30 [1■] Resin binder; 50 [unsaturated polyester] (1v) Additives; [glass fiber, curing agent, lubricant] 5 total 100 (c) The resin raw material The mixture was injected and filled into the mold prepared in (a) and cured.

(d) The mold was evacuated to obtain a columnar molded product in which the resin-rich resin surface layer and the aggregate (filler)-rich base layer were integrated. The surface of the molded product was smooth and had good luster and luster, and had a deep natural stone-like pattern.

(Example 2) (a) Glass fiber and polyester resin were simultaneously sprayed onto the inner surface of a planar mold, and glass fiber and polyester resin were simultaneously sprayed onto the back surface to form a base layer of FRP with a thickness of 20 mm.

(c) The m-frame was demolded to obtain a panel-shaped molded product in which the resin-rich resin resin surface layer and the FRP base layer were integrated. The surface of the manufactured product was smooth and had good luster and luster, and had a deep natural stone-like pattern, and was lightweight, making it suitable for use as an interior or exterior material for buildings.

In addition, in addition to the above examples, by changing the type and combination of aggregates,
Furthermore, when we carried out the same process by changing the shape of the frame, we found a rich variety of deep stone-like patterns, and found that it has extremely commercial value that can be applied to a wide range of fields, from interior e-exterior materials to E-steria supplies. A resin-containing product with high compatibility was obtained.

(Effects of the Invention) As described above, the resin molded product having the stone-like pattern of the present invention has a deep pattern with high commercial value due to the combination of the mosaic pattern of the granular aggregate and the optical effect of the transparent resin binder.・Since the surface layer, which exhibits a pattern and is responsible for the design, and the base layer, which is a reinforcing body, are integrated, it has sufficient strength required for this type of molded product, and is also lightweight and low cost. Planned.

It promises a wide range of uses, from interior and exterior building materials to various Efsteria products. In addition, in producing such a molded product, the main surface layer is obtained by spraying the mixture onto the inner surface of the mold.

It is possible to create flow patterns that have never been seen before, and it is also possible to easily produce complex shapes from flat panels, making it possible to increase the variety of molded products mentioned above. It can be said that the present invention, which has these numerous advantages, is of great value.

[Brief explanation of the drawing]

Figures 1 (a) and (b) are partial longitudinal sectional views of the molded product of the present invention, Figure 2 is a schematic process diagram of the method of the present invention, and Figure 3 (a)
→ is a schematic vertical cross-sectional view showing various molds used in the method of the present invention and their manufacturing procedure. (Explanation of symbols) 1... Surface layer part, 10--Mixture, 11-... Granular aggregate. 12-...Transparent thermosetting resin binder, 120...
・Transparent thermosetting resin liquid, 2-...Base layer part, 20...Resin concrete raw material, 200...F RP raw material, F.
...Part frame. -And more-

Claims (1)

[Claims] 1. A resin concrete surface layer 1 formed by combining natural or artificial granular aggregate and a large amount of transparent thermosetting resin binder, and a resin concrete or FRP layer containing a large amount of aggregate and filler. 1. A resin concrete molded product having a stone-like pattern, characterized in that the base layer portion and the base layer portion are integrally laminated, and the surface layer portion has a smooth molded surface. 2. The molded product according to claim 1, wherein the granular aggregate is a lump or flat granule obtained by crushing natural stone such as cold water tone, limestone, marble, and granite. 3. The molded product according to claim 1, wherein the transparent thermosetting resin binder is either a polyester resin or an acrylic resin. 4. A step of mixing natural or artificial granular aggregate with a large amount of transparent thermosetting resin liquid, and a step of spraying and fixing the mixture on the inner surface of the form and curing it to form the surface layer of resin concrete. Then, a separately prepared resin concrete raw material containing a large amount of aggregate and filler is injected into the formwork in which the surface layer is fixed, or FRP is placed on the back side of the surface layer.
A stone-like pattern characterized by comprising a step of applying and curing a raw material to form a base layer integrated with the surface layer, and a step of removing the mold to obtain a molded product. A method for manufacturing a resin concrete molded product comprising: 5. The manufacturing method according to claim 4, wherein the granular aggregate is made of massive or flat granules obtained by crushing natural stones such as kansui stone, limestone, marble, and granite. 6. Claim 4 in which either a polyester resin or an acrylic resin is used as the thermosetting resin liquid.
Manufacturing method described in section.