KR20040084228A - Method for manufacturing synthetic stone with figures on its surface - Google Patents

Abstract

PURPOSE: Provided is a method for making artificial stone, which has various types of patterns, letters and figures on the surface, without detracting from the quality of artificial stone. CONSTITUTION: The method for making artificial stone having a pattern on the surface comprises the steps of: providing a mold(1); coating a gel coat(7) on the bottom surface of the mold(1) by a screen print process to form a patterned layer; providing stone powder slurry by mixing natural stone powder with a viscous transparent polymer resin solution, and filling the stone powder slurry inside of the mold(1); and curing the stone powder slurry and separating the stone powder slurry from the mold along with the patterned layer.

Description

Method for manufacturing synthetic stone with figures on its surface

The present invention relates to an artificial stone manufacturing method having a pattern on the surface, and more particularly to an improved artificial stone manufacturing method so as to easily form a desired predetermined pattern on the surface of the artificial stone.

As materials for interior and exterior materials of furniture or furniture or crafts, tiles, wood, marble, and the like, which are generally used, are used. Among them, tiles are difficult to process or install, and have a weak disadvantage in impact, and wood is simple because the pattern or color is dependent on wood texture, and weak in heat or moisture. In addition, the marble is heavy, the pattern or color is limited to that of natural stone, the price is expensive, the reality is that the scope of use is limited.

In response to the shortcomings of the existing materials described above, artificial stones are known as materials that can replace particularly expensive marble. However, conventional artificial stone does not have a unique pattern made of patterns, letters, pictures, etc. on the surface, so it looks monotonous, and thus there is a problem in that it does not stimulate the consumer's desire to buy.

On the other hand, there is also a method of attaching the plate or paint to form a unique pattern on the artificial stone surface, which is different from the underlying artificial stone and the material causes a sense of heterogeneity, and still remains a problem that is not permanent.

The present invention has been made to solve the above problems, it is an object of the present invention to provide a method for producing an artificial stone having a surface pattern represented by various types of patterns, letters, pictures and the like.

1 is a cross-sectional view showing a process of applying a color gel coat to the bottom surface of a mold by a screen printing method.

FIG. 2 is a perspective view showing a pattern layer made of a color gel coat formed on the bottom surface of a molding die. FIG.

FIG. 3 is a perspective view illustrating a process of filling stone powder dough in the molding die shown in FIG. 2.

4 is a perspective view showing an example of artificial stone made by the method of the present invention.

5 is a cross-sectional view showing a process of spraying the color stone powder on the transparent gel coat applied to the bottom surface of the mold.

6 is a perspective view showing another example of the artificial stone made by the method of the present invention.

7 is a perspective view showing another example of artificial stone made by the method of the present invention.

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

1 ... molding frame 2 ... screen

3 ... squeegee 5 ... release agent layer

6 ,,, Gel Coat Spray Layer 7 ... Color Gel Coat

8 ... clear gel coat 11, 21, 31 ...

13, 15, 23, 25, 33 ... pattern layer 9, 24, 26, 34, 36 ...

In order to achieve the above object, the artificial stone manufacturing method having a pattern on the surface according to the present invention comprises the steps of preparing a molding die;

Forming a patterned layer by applying a gel coat to a bottom surface of the mold by a screen printing method;

Preparing a stone flour dough prepared by mixing natural stone powder and a viscous transparent polymer resin solution, and filling the interior of the mold with the stone powder dough; And

And curing the stone powder dough in the forming mold together with the pattern layer.

According to one preferred embodiment, the step of forming the pattern layer,

Mixing the transparent gelcoat and the printing ink to form a color gelcoat,

Applying the color gel coat to the bottom surface of the mold by a screen printing method;

And curing the applied color gel coat.

According to another preferred embodiment, the step of forming the pattern layer,

Applying a transparent gel coat to the bottom surface of the mold by a screen printing method;

Preparing a colored stone powder prepared by fixing an inorganic pigment to a natural stone powder, and spraying the colored stone powder on the coated transparent gel coat;

And curing the transparent gel coat to which the colored stone powder is attached.

Preferably, the color stone powder to be sprayed on the transparent gel coat is characterized in that a plurality of types of color stone powder different from each other.

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

1 to 4 are related to the first embodiment of the present invention, Figure 1 is a cross-sectional view showing a process of applying a color gel coat to the bottom surface of the mold by the screen printing method, Figure 2 is a bottom of the mold 3 is a perspective view showing a pattern layer formed of a color gel coat on a surface, and FIG. 3 is a perspective view showing a process of filling stone powder dough in the molding die shown in FIG. 2, and FIG. 4 is a method of the first embodiment. It is a perspective view showing an artificial stone having a pattern on the surface made.

Method for producing artificial stone having a pattern on the surface according to the first embodiment, the step of preparing a molding mold, forming a pattern layer on the bottom surface of the mold, and stone powder dough inside the mold The step of filling in, and after curing the stone powder dough is separated from the mold with the pattern layer.

Referring to Figure 1, the molding die 1 has a flat bottom surface, the inner space is provided to fill the stone dough 11 to be described later, the upper side is open. The mold 1 may be made of stainless steel, fiber-reinforced plastics (FRP), or silicone, but has a smooth surface to facilitate separation of the hardened stone dough (11), and is relatively inexpensive to manufacture. It is preferable to be produced with.

On the bottom surface and the side defining the inner space of the mold 1, the hardened stone dough 11 can be easily separated from the mold 1, for example, known under the trade name 'Bonlease' The mold release agent layer 5 is formed by applying a mold release agent such as this evenly. Also according to the preferred embodiment shown, a transparent gel on the release agent layer 5 on the bottom and side of the mold 1 to ensure that the finished artificial stone 10 is smooth and not easily dirty and has a shiny surface. The coat is sprayed and cured to form a gelcoat spray layer 6. In general, the gel coat is composed of an unsaturated polyester resin (Unsaturated Polyester Resin), a thermosetting resin prepared by dissolving an unsaturated alkyl obtained by esterifying a polybasic acid and a polyalcohol in a vinyl monomer monomer, and a small amount of additives are mixed with It is prepared by grinding evenly through a rolling operation. Such gel coats are excellent in water resistance, weather resistance, other mechanical and chemical properties, and are widely used in the manufacture of fiber reinforced plastics (Fiber Reinforced Plastics) products.

According to the preferred embodiment shown, a color gel coat 7 is applied to the bottom surface of the mold 1 by a so-called screen printing method. To this end, a screen 2, a squeegee 3, and a color gel coat 7 are required, and the process of screen printing using them will be described in detail as follows. First, the screen 2 is installed on the bottom surface of the mold 1. The screen 2 is made by tensioning a fabric made of silk or chemical fiber and has numerous meshes of fine size. Some of the meshes are blocked by glue or glue, as shown in black in FIG. 1, and the unopened and open meshes generally form a predetermined pattern consisting of a specific character, picture or pattern. do. Next, the color gel coat 7 is poured onto the screen 2 and then pushed out with a squeegee 3. Then, the color gel coat 7 spreads on the screen 2 and simultaneously passes through the open meshes and is applied to the bottom surface of the mold 1 in a predetermined pattern. The color gel coat 7 is made by mixing the above-mentioned transparent gel coat and the printing ink. The printing ink refers to a conventional printing ink used for screen printing of textiles and the like, and is made into a liquid state by dispersing a pigment in a colorant made by mixing oil, a solvent, a resin and the like. In some cases, it is also called dye by those skilled in the art.

When the color gel coat 7 applied by the above process is cured, predetermined pattern layers 13 and 15 are formed on the bottom surface of the mold 1 as shown in FIG. As shown in FIG. 2, the two pattern layers 13 and 15 are distinguished from each other by different colors. The two pattern layers 13 and 15 are screen-printed and cured as described above, for example, with a color gel coat of one color to form one pattern layer 13 first, followed by a color gel coat of another color. Screen printing and curing may be provided by a method of forming another pattern layer 15. Unlike in FIG. 2, it will be appreciated that when one or a plurality of pattern layers of a single color are formed, a pattern layer can be formed by screen printing and curing once with a color gel coat of one color. It will also be appreciated that a pattern layer with more complex and different colors than those shown in FIG. 2 can be formed by multiple screen printing and curing.

As shown in FIG. 3, the stone powder dough 11 is filled to a predetermined height and cured in the inner space of the mold 1 in which the pattern layers 13 and 15 are formed. The stone powder dough is a mixture of natural stone powder made of dolomite, silica sand, repair alumina and the like and viscous transparent polymer resin solution in a weight ratio of 1.5: 1 to 5: 1, and a curing agent for promoting hardening of the polymer resin solution therein. It is prepared by stirring well after addition. As the viscous transparent polymer resin solution, one may be employed in epoxy resin, acrylic resin, polyester resin, or the like. The epoxy resin is excellent in adhesion and easy to curve processing, but the price is mainly applied to high-quality products. On the other hand, the polyester resin is relatively weak in viscosity, so it is easy to remove bubbles, and has excellent surface gloss, and when cured, the shrinkage ratio is large, so that it is easy to be separated from the shaping mold 40 for forming artificial stone shown in FIG. , Can be widely used.

On the other hand, the curing agent contained in the stone powder dough 11 has a property of decomposing the ordinary printing ink. Therefore, in order to prevent the pattern layers 13 and 15 formed with patterns such as letters, pictures, patterns, etc. formed in the course of manufacturing artificial stone, as described above, the color gel coat 7 mixed with the printing ink and the transparent gel coat is used. Screen printing and curing.

The stone powder dough 11 filled in the mold 1 as described above is naturally cured at room temperature for about 4 hours, then heated to about 80 degrees Celsius, cured for about 2 hours, and left to stand at room temperature for at least 8 hours to cure. As the hardening proceeds, the stone dough dough 11 is gradually contracted, but if it is not completely cured, the artificial stone 10 which is manufactured is continuously contracted to cause deformation, so as to prevent this at about 80 degrees Celsius as described above. Curing process is required.

The stone powder dough 11 hardened as described above is deserted in the forming mold 1 together with the pattern layers 13 and 15, and is subjected to finishing surface processing, and has a pattern on the surface as shown in FIG. 4. Completed by (10).

5 to 7 relate to a second embodiment and a third embodiment of the present invention. FIG. 5 is a cross-sectional view showing a process of spraying colored stone powder on a transparent gel coat applied to a bottom surface of a molding die. 6 is a perspective view showing a patterned artificial stone on the surface made by the method of the second embodiment, and FIG. 7 is a perspective view showing a patterned artificial stone on the surface made by the method of the third embodiment.

The method of manufacturing artificial stone having a pattern on the surface according to the second and third preferred embodiments is similar to the method according to the first embodiment described above, the method of preparing a molding die, and the bottom surface of the molding die Forming a patterned layer on, filling the stone powder dough into the mold, and curing the stone powder dough and the step of separating from the mold together with the pattern layer, since the other steps are the same Hereinafter, the steps of forming the pattern layer will be described.

In order to form a patterned layer, as shown in FIG. 5, first, a transparent gel coat 8 is applied to the bottom surface of the molding die 1 by a screen printing method. Since the screen printing method is as described above with reference to FIG. 1, a description thereof will be omitted. The transparent gel coat 8 will be applied to the bottom surface of the molding die 1 in a predetermined pattern, but may not be clearly recognized as transparent. Between the transparent gel coat 8 and the mold 1, a release agent layer 5 and a transparent gel coat spray layer 6, which are sequentially laminated and cured in the same manner as described with reference to FIG. 1, are formed.

Before the transparent gelcoat 8 is cured, the colored stone powder 9 is sprinkled on the transparent gelcoat 8 as shown in FIG. 5. Then, the colored stone powder 9 adheres to the transparent gel coat 8 and a part of it penetrates into the transparent gel coat 8. After curing the transparent gel coat 8, the colored stone powder 9 scattered on the bottom surface of the mold 1 is sucked and cleaned with a vacuum cleaner, and the transparent gel coat 8 is applied in a predetermined pattern. The colored stone powders 9 are fixedly distributed only in the areas where they are formed, thereby forming a pattern that can be clearly identified by eyes. However, the colored stone powder 9 shown in FIG. 5 is exaggerated for clarity of recognition, and the actual colored stone powder may be different in size and shape from those shown.

The color stone powder (9) is made by fixing the inorganic pigment to the natural stone powder, if you look at the manufacturing process schematically as follows. First, an inorganic pigment is added to the alcohol to dissolve it, and an acrylic adhesive is added thereto to make a mixed solvent, and natural stone powder including dolomite and silica sand is added thereto. Next, the inorganic pigment is allowed to penetrate the natural stone powder well for a predetermined time, and then burned with alcohol to obtain colored stone powder 9. The colored stone powder 9 is distinguished from each other according to the color of the inorganic pigment to be added, it can be made in various kinds.

After filling the stone powder dough in the forming mold (1) formed with a pattern layer in the same manner as above, and curing it, after desertification and finishing surface processing, the artificial stone having a pattern on the surface is completed.

Referring to FIG. 6, the artificial stone 20 according to the second embodiment is made by curing the stone powder dough 21, and has two patterned layers 23 and 25 separated from each other on an upper surface thereof. The patterned layers 23 and 25 are sprayed with different kinds of colored stone powders 24 and 26 having different colors. This is applied by screen printing a transparent gel coat 8 (see FIG. 5) on the bottom surface of the mold 1 (see FIG. 5) so as to correspond to the circular shapes of the pattern layers 23 and 25. It can be implemented by spraying the colored stone powders (24, 26) to (23, 25), respectively. However, the colored stone powders 24 and 26 shown in FIG. 6 are exaggerated for clarity of recognition, and are shown in rectangular and triangular shapes for easy discrimination. Therefore, the particles of the actual color stone powder may be different in size and shape as shown.

Referring to FIG. 7, the artificial stone 30 according to the third embodiment is made by curing the stone powder dough 31, and has one pattern layer 33 on the upper surface thereof. The pattern layer 33 has a shape similar to a cross section of a dumbbell, and has circular end portions 33a and 33c and a joint portion 33b connecting the both ends 33a and 33c. Different kinds of colored stone powders 34 and 36 having different colors are sprayed on both ends 33a and 33c of the pattern layer 33, and the different type of colored stone powders are formed on the joint 33b. (34, 36) are mixed and scattered. This is applied by screen printing a transparent gel coat 8 (see FIG. 5) on the bottom surface of the mold 1 (see FIG. 5) so as to correspond to the shape of the pattern layer 33, and on both sides of the pattern layer 33. The colored stone powders 34 and 36 are sprinkled on end portions 33a and 33c, respectively, so that the colored stone powders 34 and 36 are suspended in the transparent gel coat 8 and are joined to each other at the joint portion 33b. This can be achieved by mixing them together. However, the colored stone powders 34 and 36 illustrated in FIG. 7 are exaggerated for clarity of recognition, and are shown in rectangular and triangular shapes for easy discrimination. Therefore, the particles of the actual color stone powder may be different in size and shape as shown. As described above, since the color stone powders 34 and 36 are mixed in the pattern layer 33, atypical color patterns may be realized in the pattern layer 33, thereby completing the artificial stone 30. Can have a luxurious feel.

Although the present invention has been described with reference to the embodiments shown in the drawings, this is merely exemplary, and it will be understood by those skilled in the art that various modifications and equivalent other embodiments are possible. For example, the stone powder dough forming the artificial stone may be a colored stone powder in which color stone powder distinguished from the color of the pattern layer, a viscous transparent polymer resin liquid, and a curing agent are mixed, as described above. Therefore, the true scope of protection of the present invention should be defined only by the appended claims.

Artificial stone manufacturing method having a pattern on the surface according to the present invention, by screen printing a color gel coat, or by screen printing a transparent gel coat and spraying the color stone powder, so that a pattern having a variety of colors and various patterns can be expressed By doing so, it is possible to avoid the monotony of the artificial stone and to stimulate the purchase desire of the consumer.

In addition, since the pattern is not formed by attaching or painting the surface of the artificial stone, there is no sense of heterogeneity between the base and the pattern of the artificial stone, and thus a colorful pattern may be expressed on the surface of the artificial stone. Dignity is not damaged.

Claims (4)

Preparing a mold; Forming a patterned layer by applying a gel coat to a bottom surface of the mold by a screen printing method; Preparing a stone flour dough prepared by mixing natural stone powder and a viscous transparent polymer resin solution, and filling the interior of the mold with the stone powder dough; And And hardening the stone flour dough and separating the mold from the mold together with the patterned layer. According to claim 1, Forming the pattern layer, Mixing the transparent gelcoat and the printing ink to form a color gelcoat, Applying the color gel coat to the bottom surface of the mold by a screen printing method; And a step of hardening the applied color gel coat. According to claim 1, Forming the pattern layer, Applying a transparent gel coat to the bottom surface of the mold by a screen printing method; Preparing a colored stone powder prepared by fixing an inorganic pigment to a natural stone powder, and spraying the colored stone powder on the coated transparent gel coat; And a step of hardening the transparent gel coat to which the colored stone powder is attached. The method of claim 3, wherein The method for producing artificial stone having a pattern on the surface, characterized in that the colored stone powder sprayed on the transparent gel coat is a plurality of kinds of colored stone powders different in color from each other.