KR100526373B1 - Apperatus For Continious Manufacturing Acrylic Artificial Marble Plate - Google Patents

Abstract

The present invention relates to a continuous manufacturing apparatus of acrylic resin artificial marble plate, the acrylic resin artificial marble plate polymerization raw material mixture is continuously put into a continuous curing apparatus consisting of a set of endless steel belt and an auxiliary device and cured to produce a plate-like semi-finished product After manufacturing, through the process of edge trimming and surface polishing, acrylic resin marble sheet is produced in a continuous curing device, and two sets of rubber retainer belts and retainer belts reinforced with nylon fibers as a width control device for the product, and a support ball By attaching a device consisting of a positioning device, etc. to easily adjust the width of the product is characterized in that it is possible to manufacture a wide range of products, by using a set of steel belts by the device of the present invention easily The width of the product can be adjusted.

Description

Apparatus For Continious Manufacturing Acrylic Artificial Marble Plate}

The present invention relates to a continuous manufacturing apparatus of artificial marble plate using an acrylic resin composition, and more particularly, a continuous curing apparatus using a set of endless steel belts using a mixture of a large amount of inorganic filler mixed with an acrylic polymerizable resin. It is related with the continuous manufacturing apparatus of the acrylic resin artificial marble plate which hardens and manufactures it.

Acrylic artificial marble is prepared by mixing a large amount of powdery inorganic fillers, marble patterning particles, marble additives, various additives, curing initiators and pigments in an acrylic polymer resin to prepare a slurry phase mixture and injecting the same into a mold. After hardening in a suitable curing device, the product is manufactured through edge trimming and surface polishing. It is made of non-porous material with the same surface as the inside, and is cut, polished, and heated. It is easy to bend and bond with adhesives, and demand for building interior materials such as kitchen sink tops, counters, sinks, and wall materials is increasing.

Such acrylic artificial marble is generally manufactured by two methods, a casting method and a continuous manufacturing method.

The molding method is disclosed in European Patent No. 66951, European Patent No. 516299, European Patent No. 285046, Japanese Patent Application Laid-Open No. 52-36155, Japanese Patent Application Laid-Open No. 53-112990, and the like.

Molding method is to put resin gasket on 2 sheets of metal plate or glass plate, inject the mixture into the mold crimped with clamp, and harden it in the mold after the 1st and 2nd curing in water tank or air circulation oven. It is a method of obtaining a product. However, since this method is a batch operation, the operation is complicated, the manufacturing cost is increased, and the productivity is very low. Therefore, rationalization by serialization has been desired.

The continuous manufacturing method of sequencing the casting method as described above is not directly disclosed in the patent, but a continuous casting method of the acrylic plate containing no minerals (US Pat. No. 4,133,861 and No. 47-34815) It is a method that is developed by general Matsubishi Rayon and applied to production. This method consists of two sets of endless steel belts installed vertically with opposite sides running at the same direction and at the same speed, a device for continuously supplying resin gaskets between the sides of the belt in the width direction, and appropriate heating and cooling devices. The mixture is continuously injected into a space formed by a belt and a gasket in a curing device composed of the back and the like, and cured in accordance with the movement of the belt to take out the plate-shaped product from the outlet of the device.

However, according to the above method, the upper belt among the facing belts is struck down by its own weight, and the thickness nonuniformity of the product in the width direction occurs. Therefore, it is necessary to maintain proper hydraulic pressure between the belt surfaces to prevent this. For this purpose, a special device must be fitted to the mixture inlet.

In addition, because the steel belt is bent between the lower support roll and the upper press roll of the facing belt, it is difficult to prevent leakage at the gasket sealing area, and the mixture gradually hardens as the volume hardens and shrinks. There is a hassle to reduce the compression roll spacing.

In addition, when the thickness of the product is changed, the total support and the distance between the pressing rolls are complicated, so that the investment cost is increased and the reuse of the resin gasket is difficult, so the operating cost is shortened. In addition, it is difficult to control the process, there is a problem that defective products such as sink mark (Sink Mark) due to shrinkage of the product when mixing bubbles, curing.

As an alternative to solving the problem of the continuous manufacturing method using two sets of endless steel belts as described above, there is a method using one set of endless steel belts.

This method is a method disclosed in Korean Patent Application No. 97-3221. When a set of steel belts is used as a continuous curing device, it is easy to adjust the thickness of the product by means of a suitable mold and thickness adjusting device, and a rubber retainer on the belt. It is easy to prevent leakage of the mixture at the time of casting and curing by attaching a suitable resin film to the surface of the belt and the surface of the mixture to facilitate product release from the belt and to prevent volatilization of the polymerizable monomer.

Therefore, there is an advantage that it is possible to manufacture a product without appearance defects such as thickness variation in the width direction, crack bubbles, and sink marks with a relatively simple device with high productivity.

However, in the case of using a set of steel belts as a curing device, in order to prevent leakage of the mixture during casting and hardening, a conventional method is to attach a rubber retainer by attaching and fixing a band-shaped rubber retainer to the surface by an adhesive. Since the movement of the product is very difficult to control the width of the product, the width of the produced product is fixed and it is difficult to meet various demands of the market.

It is an object of the present invention to overcome the problems of the prior art as described above, by using a set of endless steel belts as a curing device, in the manufacture of acrylic resin artificial marble plate, it is possible to adjust the rubber retainer in the width direction of the product. It is to provide a device that can produce a wide range of widths.

The present invention is continuously injected into the curing device consisting of a set of endless steel belt and the auxiliary device of the acrylic resin artificial marble plate polymerization raw material and cured in accordance with the movement of the steel belt to produce a cured plate-like edge trimming and surface In the manufacture of acrylic resin artificial marble through polishing process, a continuous belt consisting of a retainer belt, a retainer belt tensioning device, a retainer belt support roll, and a retainer belt positioning device as a set of steel belts as a product width adjusting device It is characterized in that installed in the curing device.

Hereinafter, the present invention will be described in detail with reference to the accompanying drawings.

The continuous curing apparatus of the present invention is composed of a set of endless steel belts and auxiliary devices.

1 is a side view of an acrylic resin continuous production apparatus using a set of endless steel belts according to the present invention, the product width variable device is attached.

The V-rope 19 is attached to the lower surface of the endless steel belts (1, 1 '), and the steel belt is moved at a constant speed by the driving pulley (2') driven by the motor (4) and the tension is adjusted. Deflection is prevented by the tension applied by the idle pulley 2 with the device installed and the support rolls 3 and 3 'to ensure the required flatness. Tensile force is better in terms of maintaining the flatness of the belt, but 3 to 15 kg / mm ² is common.

The V-rope 19 is a rubber material and is attached to the lower part of the belt to prevent meandering of the belt during the circular drive of the steel belt.

5 is a hardening chamber with a hot air circulation system for heating and cooling the steel belt and the raw material mixture.

6 to 11 are synthetic resin film coating apparatuses which continuously apply a film to the steel belt surface (raw material bottom surface) and the raw material mixture top surface. Figure 6 is an oil coating device that applies viscous oil to the belt surface to improve the adhesion between the film and the belt surface when the resin film is applied to the belt surface. 7 and 11 are film roll unwinders with a tension regulator, 8 and 11 are guide rolls for preventing wrinkles of the film, and 9 are press rolls for applying the film to the steel belt surface. 13 is a raw material supply device for uniformly dispersing the raw material mixture in the space formed by the steel belt surface and the retainer 18.

12 is a roller type adjusting device for adjusting the thickness of the mixture, 14 to 17 is a device for adjusting the width of the product, consisting of a drum driven by the idler and a tension applying and adjusting device, and 16 is a retainer belt position adjusting device. , 17 is a retainer belt support roll.

Fig. 2 shows an endless steel portion in which a raw material mixture 20 is loaded in a continuous manufacturing apparatus without a product width adjusting device as a reference figure, wherein the rubber retainer 18 is bonded and fixed to the steel belt surface as an adhesive.

FIG. 3 is a cross-sectional view of the endless steel belt portion in which the raw material mixture is loaded in the continuous production apparatus of which the product width is variable, and the retainer belt 14 is movable in the width direction by the retainer belt position adjusting device 16.

When manufacturing the acrylic resin artificial marble plate according to the present invention, 100 parts of the acrylic resin syrup (Syrup) 110 to 300 parts of the inorganic filler, a small amount of the dispersant, the crosslinker light stabilizer and the pigment are mixed in a stirred mixer and degassed under vacuum Prepare acrylic resin artificial marble mixture. Subsequently, the obtained mixture is continuously added to a static mixer by a metering pump, and the curing initiator is added and mixed, followed by mixing into a continuous apparatus of the present invention.

The acrylic resin artificial marble plate mixture mixed with the curing agent is continuously fed onto a steel belt coated with a synthetic resin film on the surface via a raw material mixture supply device. The raw material mixture supply apparatus is provided with a circular nozzle reciprocating in the width direction to uniformly disperse the mixture in the width direction.

The injected mixture is moved by a belt, and a synthetic resin film is applied to the surface, and the thickness is uniform in the width direction by the roller-type thickness adjusting device, as shown in FIG. 3, and then transferred into the curing chamber. The raw material mixture transferred into the curing chamber is discharged to the outlet of the device after it is cooled to the extent that the curing reaction is complete and no subsequent deformation occurs during the passage of the curing chamber. The curing chamber is equipped with a high temperature air circulation system to promote the curing reaction by heating and to cool the cured product without the occurrence of warp in the width direction.

Finally, the artificial marble cured product passed through the hardening chamber is continuously cooled to room temperature in a separate cooling device, and then cut into the required dimensions by the cutting device.

The acrylic artificial marble mixture applied to the present invention is composed of the following components. The polymerizable resin component may be methyl methacrylate (MMA) alone, or an alkyl acrylate (C ₁ -C ₈ ) ester capable of copolymerizing therewith, alkyl methacrylate (C ₂ -C ₈ ) ester, halogen or alkyl of styrene styrene ( C _{1 ~} C ₂ ) derivatives, etc., are mixed up to 30% by weight, and partially polymerized in a continuous or batch reactor for process suitability or by dissolving polymethyl methacrylate (PMMA) in MMA for polymer content of 10 to 35 It is prepared and used in the form of acrylic syrup in the range by weight.

The inorganic filler is 110 to 300 parts by weight based on 100 parts by weight of resin, including fine powder alone such as calcium carbonate, aluminum hydroxide, talc, or granular marble chips having a particle diameter of 0.1 to 5 mm. It is not important in the present invention.

In addition, the additives for improving the process aid and physical properties use a small amount of a surfactant, a releasing agent, a light stabilizer, a crosslinking agent, a coupling agent, etc., as necessary, in a range that does not significantly lower the curing rate. The curing agent may be a redox type initiator using a thermal decomposition type radical initiator or an accelerator, but preferably, a plurality of combinations of those having a half-life temperature of 70 ° C. or lower or a combination of those of 70 ° C. or lower and 10 ° C. or less are preferably used. do.

Hereinafter, the product width adjusting device will be described in more detail.

The movable retainer belts should have physical properties, structures and shapes that meet the required conditions. As a condition of the material, the retainer belt circulates inside the high-temperature curing chamber maintained at 100 to 130 ° C so that there is no phenomenon of aging due to heat and the viscosity used as the release oil is in contact with the release oil applied to the steel belt surface. There should be no deterioration of physical properties by the centipoase level paraffin oil and have a tensile strength corresponding to the tension applied to move the retainer belt without slipping with the steel belt and to maintain the straightness of the retainer belt.

As the requirements of the retainer belt structure and shape, the raw material mixture and the contact area should have a structure suitable for the retainer role to prevent leakage of the raw material mixture, and the area in contact with the retainer belt positioning device prevents the deviation from the adjusting device and adjusts the position. It should have a structure that is suitable for maintaining accuracy.

In addition, since the retainer belt bends at the same radius as the pulley radius at the driving pulley of the steel belt and at the same radius as the idle drum at the retainer belt tensioning device, the retainer belt must have flexibility for bending and a long time under tension. There should be no shape deformation when used.

The material and structure satisfying the above conditions are preferably reinforced with nylon-based cord fibers and the like in NBR (Acrylronitryl Butadiene Rubber) -based rubber as shown in Figure 4a.

The higher the hardness of the rubber is better in terms of tensile strength and oil resistance, but the flexural flexibility is inferior, so 60 to 70 is preferred as Showa hardness.

The reinforcing material may be nylon cord paper, polyester cord fiber paper, steel cord, but nylon cord fiber paper having excellent physical properties and molding processability is preferable.

The reason for the trapezoidal shape of the liquid contact portion in the shape of the retainer belt is to prevent the formation of wrinkles on the bottom surface upon application of the release film and to facilitate product release on the steel belt surface at the exit of the device. The reason for the trapezoidal positioning is to prevent the retainer belt from falling off the roll of the positioning device and to increase the accuracy of the positioning.

In the device for imparting tensile force of the retainer belt, the purpose of imparting tensile force is to generate frictional force in the steel belt drive pulley (2 ') to move the retainer belt, prevent slipping with the steel belt, and linearity of the rubber belt. This is to ensure uniformity of product width by securing The preferred device is an idle drum mounted on a cart that moves easily in the longitudinal direction of the steel belt for tension adjustment. The width of the idle drum must be greater than the sum of the product width adjustment range and the retainer belt width. Larger is preferred for flexural load of the retainer belt but should not be larger than the diameter of the steel belt tension pulley. Preferably, 70 to 90% of the diameter of the steel belt tension pulley is suitable.

The tensile force of the retainer belt is generated by pushing the trolley in the opposite direction to the steel belt with an air cylinder, a spring, etc., which is a tensioning force applying device, and the magnitude of the tensile force is preferably maintained so that no slip occurs in the steel belt.

Retainer belt position adjusting roller device adjusts the width of the product by adjusting the position of the retainer belt, which is the upper part of the steel belt, and consists of a grooved roller and a position adjusting screw to accommodate the retainer belt outer profile. It is installed in the frame of the steel belt or the frame of the curing chamber. The pitch of the screws is preferably 4 to 5 mm and the spacing between the roller devices is preferably 1 to 2 m.

Retainer support roller is to prevent the retainer belt from sagging at the lower part of the steel belt and to make contact with the steel belt to generate friction force. The structure is 60 to 100mm in diameter and the length of the roller is almost the same as the width of the steel belt. The top height is set to be lower than the height of the steel belt support roll by the retainer belt height, and the distance between the rollers is preferably 3 to 4 m.

In order to adjust the width of the product as the product width variable device, the device must be adjusted before the input of raw materials. As a preliminary step of adjustment, replace the oil coating of the release oil applicator with the compression roll of the lower film applicator and the thickness control device with a standard product that fits the inner width of the retainer belt. Adjust the inner width of the retainer belt to the desired product width.

Therefore, the method and apparatus of the present invention are not only simpler than two sets of endless steel belt hardening apparatuses in the manufacture of acrylic artificial marble, but also can easily adjust the width of the product with less consumables such as synthetic resin gaskets.

Hereinafter, the present invention will be described in detail with reference to Examples, but the scope of the present invention is not limited to Examples. Compositions are by weight unless otherwise specified.

<Example 1>

Steel belt drive and tension pulley with diameter of 1,000mm, center distance of pulley 20m, steel belt width 1,200mm, thickness 1.0mm Endless belt device and auxiliary device, release oil coating device, raw material mixture supply device, film coating device And a retainer belt, a tension imparting device, a position adjusting device, and a support roller, which were movable as a width adjusting device, were installed and adjusted in a curing device composed of a thickness adjusting device and a curing chamber, and an acrylic polymerizable raw material was added to operate the device.

The retainer belt was formed by inserting two layers of nylon coded paper into NBR rubber with a shape as shown in FIG. 4A. The idler drum of the retainer belt tensioning device has a width of 220 mm, a diameter of 700 mm, and an air cylinder attached to the drum bogie. Tension was adjusted.

The retainer belt position adjusting device has the shape of FIG. 3, and the structure of the adjusting roll is grooved to accommodate the trapezoidal rubber profile of the retainer belt and is installed in contact with the rubber profile. The adjusting stroke of the position adjusting screw is up to 100 mm and the adjusting screw The pitch of is 4mm.

The diameter of the supporting roll is 100mm and is installed 25mm lower than the height of the steel belt supporting roll at the bottom of the steel belt, and the distance between the rolls is 4m.

In order to produce products with a width of 1,800 mm, the application roll, the thickness adjusting roll of the thickness adjusting device, the lower film applying device and the pressing roll having a length of 810 mm are mounted on the release oil coating device, and the position of the retainer belt is adjusted between the belts. The inner force of the resin was 820 mm, and the tensioning force applied to the retainer belt was adjusted to about 400 Newton by adjusting the retainer belt tensioning force applying device. The release oil used paraffin oil with a viscosity of 50 centipoase level and the release film used a 60 micron Viniron film.

The acrylic resin mixture is added to 200 parts of alumina hydroxide, a small amount of dispersant, a crosslinking agent, and a pigment in 100 parts of acrylic resin, mixed in a stirred mixer, degassed under vacuum, and mixed with a curing agent in a separate continuous mixing device, and then into the input device. While moving at 10.0 kg / min, the moving speed of the steel belt was operated at 0.5 m / min to obtain an artificial marble plate hardened product.

The width of the cured product was 798 to 802 mm and the thickness was 14.8 to 15.2 mm.

In order to produce 950mm product width, the size of mold roll of release oil coating device, thickness control roll of thickness adjusting device, and film compression roll for lower part is equipped with 965mm form of mold and inner diameter is adjusted by adjusting retainer belt. It was adjusted to be 975 mm.

The same polymerizable raw material mixture as in the first stage was introduced into a device operating at 0.5 m / min at a flow rate of 11.9 Kg / min and cured to obtain a plate-shaped cured product having a width of 948 to 992 mm and a thickness of 14.8 to 15.2 mm. Using the device for about one year, there was no breakage or deformation of the retainer belt and no device problems such as scratching of the steel belt.

Comparative Example 1

The same product width adjusting device as in Example 1 was installed in the continuous curing apparatus provided with the same endless steel belt apparatus and the auxiliary apparatus except for the retainer belt, and the apparatus was operated.

The outer structure of the applied retainer belt is the same as that of Fig. 4b, and the NBR rubber strip-shaped retainer was bonded to a narrow stainless steel belt having a width of 100 mm and a thickness of 1.0 mm with a two-part rubber adhesive.

When using the same raw material as in Example 1 and operating under the same curing conditions, when the tensile force applied to the individual retainer belt was 800 Newton (Kgm / sec ² ) or less, slipping occurred in the retainer belt and the steel belt to apply the release film for the lower part. Wrinkles are formed on the retainer belt area, and wrinkles are formed on the edges of the bottom of the product.In order to prevent slippage, it operates for about 1 month with a tension force of about 900 Newton (kgm / sec ² ). Severe scratches occurred on the steel belt surface.

Comparative Example 2

In the continuous curing apparatus provided with the same endless steel belt apparatus and the auxiliary apparatus as in Example 1, except for the retainer belt, the same product width adjusting apparatus as in Example 1 was installed and the apparatus was operated.

The outer structure of the applied retainer belt is the same as that of Fig. 4c, and the NBR rubber band retainer is bonded to a small stainless steel belt having a width of 100 mm and a thickness of 1.0 mm with a two-component rubber-based adhesive to narrow the problems caused in Comparative Example 1. On the bottom of the steel belt, a plate rubber having a thickness of 3 mm of NBR rubber was attached with the same adhesive.

Using the same raw materials as in Example 1 and operating the apparatus under the same conditions, the slipping and scratching problems which occurred in Comparative Example 1 did not occur, but after about one month of operation, the plate rubber under the retainer belt was reduced in the narrow steel belt. Peeling phenomenon occurred.

As can be seen through the above embodiment, the apparatus of the present invention can continuously manufacture the artificial marble plate in which the width of the product is varied.

1 is a side view of an acrylic resin continuous manufacturing apparatus using a set of endless steel belt according to the present invention, the product width variable device is attached.

FIG. 2 is a cross-sectional view of an endless steel belt portion in which a raw material mixture is loaded in a continuous manufacturing apparatus using a set of endless steel belts and having a fixed product width; FIG.

3 is a cross-sectional view showing an endless steel belt portion in which a raw material mixture is loaded in a continuous production apparatus of a variable product width.

Figure 4 shows the various forms of the retainer belt for product width adjustment,

a is formed by reinforcing the fiber component to a rubber-based material,

b is a band-shaped rubber retainer bonded to a narrow steel belt,

c is a rubber plate attached to the lower part of b.

<Description of the symbols for the main parts of the drawings>

1: Steel belt (top) 1 ': Steel belt (bottom)

2: idle pulley 2 ': driving pulley

3: belt support frame (upper) 3 ': belt support frame (lower)

4: drive motor 5: curing chamber

6: release oil coating device 7: lower film supply device

8: guide roll 9: lower film pressing roll

10: upper film feed device 11: guide roll

12 thickness control device 13 raw material supply device

14 retainer belt 15 idler drum for retainer belt

16: retainer belt position adjusting device 17: retainer belt support roll

18: fixed retainer 19: V rope (Rope)

20: raw material mixture 21: rubber belt

22: fiber reinforcement 23: band-like rubber retainer

24: narrow steel belt 25: rubber plate

Claims (3)

In the production of artificial marble plate in which a large amount of inorganic filler is mixed with an acrylic polymerizable resin, a rubber retainer belt 14 which is movable as a product width adjusting device to a continuous curing device using a set of endless steel belts as a curing device and A continuous production apparatus of artificial marble, characterized in that the idler drum (15) for the retainer belt, the retainer belt position adjusting device (16), and the retainer belt support roll (17) are mounted. The method of claim 1, wherein the retainer rubber belt (14) is made of NBR rubber-based reinforcement of the nylon fiber material is formed inside, the continuous manufacturing apparatus of artificial marble plate, characterized in that attached to the trapezoidal profile for position adjustment. 3. The artificial marble according to claim 2, wherein the retainer belt (14) tension force adjusting device is composed of a drum installed at the front end of the steel belt idle drum (15) and driven by an idler and an air cylinder or spring which is a tension force applying device. Continuous manufacturing apparatus of plate.

Images