JP2929941B2 - Artificial stone and method for producing the same - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

The present invention relates relates to an artificial stone and a manufacturing method thereof, and more particularly, it is possible to expose the Granite-like appearance, such as artificial marble, and artificial stone having a fire resistance And its manufacturing method.

[0002]

The finite nature of the Prior Art] natural resources and in view of the cost problem, artificial stone having a conventional than people artificially manufactured the various patterns is known.

As such an artificial stone, for example, an artificial stone having a structure shown in FIG. 6 is known. In the figure, the artificial stone 50 has a filler 5 in a resin 51 having translucency.
2 is filled. As the filler 52, glass flakes, frit, aluminum hydroxide, and the like for expressing transparency or depth, and mica, metal pieces, and the like for expressing brilliancy are used. Thus, an artificial stone 50 capable of exhibiting a granite appearance through the irregular reflection of incident light can be obtained.

In producing such artificial stone 50, for example, extrusion molding or the like is used in which a filler is mixed into predetermined resin pellets, and this is extruded from a molding die to obtain a plate-like body. I have.

[0005]

However, in the above-described artificial stone 50, the resin 51 occupies the entire area other than the filler 52, so that the amount of the resin used is large and it is easy to burn. Therefore, there is an inconvenience that application to a fire-resistant structure is difficult. In this regard, it is conceivable to apply painting, printing, decorative film, laminating, etc. on non-combustible materials in consideration of fire protection, but in this case, the amount of resin as a construction target will be limited. However, it is easy to become a flat artificial stone that cannot obtain the expected depth or three-dimensional effect, and an artificial stone that can exhibit an excellent appearance in design cannot be obtained. Moreover, according to the resin amount as described above, the weight of the entire also increases, disadvantageously becomes difficult to reduce the weight of the Tsu Oh.

Further, when glittering flakes are mixed in the filler 52, when the glittering flakes are wet with the resin, the gloss is rather increased due to the close refractive index of light between the resin and the flakes. The inconvenience of disappearing also comes.

Further, in the conventional structure, the filler 52
Is a structure completely embedded in the resin 51, the manufacturing method is also limited to a so-called wet molding method such as extrusion molding,
Inevitably, expensive molding dies must be used, which has contributed to an increase in manufacturing costs.

[0008]

SUMMARY OF THE INVENTION The present invention has been devised in order to improve the disadvantages of the prior art. The purpose of the present invention is not only to obtain the expected decorative appearance but also to reduce the amount of resin used to prevent fire. The structure can be made to be excellent in performance, and at the same time, maintaining a certain strength and maintaining the heat insulation effect while reducing the weight as a whole, and expanding the selection range of manufacturing methods to reduce costs An object of the present invention is to provide an artificial stone that can be manufactured by using a method and a method for manufacturing the same.

[0009]

[0010]

In order to achieve the above object,
Because, engagement Ru human engineering stones to the invention, the inter-inorganic granules mutually coated with a resin material having a light transmitting property in point contact bonded, a plate-like member having a predetermined intergranular gap, the plate-like member providing a surface layer having a light-transmitting property on at least one surface of, it adopts a configuration that.

Further, the artificial stone according to the present invention is characterized in that the inorganic particles coated with a resin material having a light-transmitting property are connected by point contact with each other to form a plate having a predetermined intergranular gap. A configuration in which a light-transmitting surface layer is provided on one surface of the body and a base material layer is provided on the other surface is also adopted, thereby achieving the above object more effectively.

[0012]

[0013] manufacturing process of engaging Ru artificial stone of the present invention, after setting the surface layer forming a light-transmitting material, coated with a resin material having a light-transmitting property on one surface of the surface layer forming material inorganic The method employs a method in which the granular material is sprayed, and then the surface layer forming material and the inorganic granular material are hot-press-molded so as to enable point contact bonding while maintaining a predetermined amount of the intergranular space of the inorganic granular material.

In the above-mentioned production method, it is preferable that after the inorganic granular material is sprayed, the base material is further laminated and subjected to hot press molding.

Still another manufacturing method according to the present invention is to laminate an inorganic granular material coated with a resin material having a light-transmitting property and a base material forming material, and to maintain a predetermined amount of intergranular space of the inorganic granular material. A method of hot-press-pressing the substrate layer molding material and the inorganic granular material so as to enable point contact bonding while forming a light-transmitting surface layer on the surface of the inorganic granular material is also adopted. .

In the present invention, the state in which the coated inorganic particles are in point contact bonding with each other is defined as:
The inorganic particles may be in direct contact with each other or may be in contact with each other via a resin material.

[0017]

The inorganic granular material coated with the resin material is point-contact-bonded to each other in a state where a predetermined amount of intergranular space is formed. A structure that is sufficient to achieve, thereby facilitating application to refractory structures. On the other hand, the internal intergranular gap reduces the weight of the artificial stone as a whole and also exhibits heat insulation.

The surface of the inorganic granular material after molding is wet with the coating resin, and the inorganic granular material is deepened in combination with the transparency of the granular material, and gives a three-dimensional appearance to the appearance. Further, in the region that is in contact with the gap, the light is reflected favorably and more shine is exhibited.

In the present invention, the inorganic granular material includes colored silica sand, glass frit, fine quartz, silica, natural marble ground particles, sand, cold water stone, colored cold water stone, ceramic ground particles, ceramic sintered particles, mica, and colored. Mica and the like are exemplified, and those having a particle size of 0.1 to 5 mm are employed. However, in order to maintain good appearance and surface smoothness, it is preferable to employ an inorganic particulate material having a particle size of 0.1 to 2 mm. The resin that coats the inorganic granular material and acts as a binder includes:
Thermoplastic resin such as polycarbonate, PS, ABS, acrylic, polyester, EVA, vinyl chloride, or acrylic, polyester, urethane, phenol,
Thermosetting resins such as melamine, epoxy and fluorine are used. The inorganic particles coated with these resins have an intergranular gap of 10 to 50% by volume, preferably 30 to 4% by volume.
Hot press molding is performed so that 0% by volume can be secured. If the intergranular gap is less than 10% by volume, the brightness based on light reflection in the region in contact with the gap will be insufficient, while if it exceeds 50% by volume, the strength reliability tends to be reduced. When the intergranular gap is in the range of 30 to 40% by volume, both fire prevention performance and strength are achieved. The amount of the resin for coating the inorganic particles is 1 to 20% by weight, and preferably 2 to 10% by weight in consideration of the quasi-nonflammability. Also, the layer thickness of the decorative layer as a whole
0.5 to 20 mm can be exemplified.

As the surface layer in the present invention, a sheet material such as vinyl chloride, polyester, acryl, ABS and PS can be employed, and it can be formed by a coating film of acryl, polyester, urethane or the like. The thickness or thickness of the surface layer formed of these resin materials is 0.05
The thickness is preferably set to 1.0 to 1.0 mm, and more preferably 0.05 to 0.4 mm in order to achieve semi-flammability. In the configuration in which the surface layer is provided, it is possible to further improve the appearance performance such as protection of the surface of the plate-like body, depth, and three-dimensional appearance.

The base material layer can be formed by using inorganic granular material or by using relatively inexpensive lightweight aggregate. In these cases, it is preferable to additionally use a resin-impregnated glass in order to realize a certain reinforcement,
Examples of other molding materials for the base material layer include non-combustible plate materials such as cement asbestos plate, calcium silicate plate, and steel plate. Although it is not necessary to provide this base material layer,
It is provided in order to obtain a thickness with an inexpensive member having inferior appearance performance when reinforcing a plate-like body or an artificial stone requires a thickness. In addition, when providing a base material layer, it is preferable to set it as 20 mm or less in order to achieve weight reduction.

[0022]

Embodiments of the present invention will be described below with reference to the drawings.

FIG. 1 is a typical sectional view of a layered structure of the artificial stone 10 of the present embodiment, and FIG. 2 is a partially enlarged sectional view of FIG. In these figures, artificial stone 1
Reference numeral 0 includes a surface layer 11, a decorative layer 12, and a base material layer 13 from above in FIG. The surface layer 11 is formed by a transparent resin layer or a coating film, and the layer or the film thickness is set to 0.05 to 1 mm.

The decorative layer 12 includes an inorganic granular material 12A having a particle size of 0.1 to 5 mm.
-20% by weight of a transparent resin 12B is coated as a binder resin, and the particles are bonded in a state of point contact with each other. This inorganic granular material 12A is shown in FIG.
As shown in the enlarged view in FIG.
It is hot-pressed so that 0 to 50% by volume can be secured.
The external shape is formed in a plate shape.

As shown in FIG. 1, the base material layer 13 is made of an inorganic granular material 13 having the same composition as the decorative layer 12.
A and a non-combustible board 13B.

In manufacturing the artificial stone 10 having the above configuration, first, a molding material for the surface layer 11 is set on a platen of a press molding machine (not shown), and then an inorganic material which is a molding material for the decorative layer 12 is formed on the surface layer 11. A predetermined amount of the granular material 12A is sprayed. On the upper surface side of the decorative layer 12, a molding material of the base material layer 13 is set, and an artificial stone 10 having a predetermined thickness is formed by placing a base plate facing the molding material and performing hot-press molding. The surface layer 11 of the artificial stone 10 thus obtained is
After that, it is ground and polished as necessary, and is subjected to a separate coating finish or the like.

Next, more specific examples of the present invention will be described in detail with reference to comparative examples.

Example 1 In this example, a sheet of transparent polyethylene terephthalate having a thickness of 0.1 mm was used as the surface layer 11, and the particle size of the sheet coated with the unsaturated polyester resin so as to be 3% by weight of the unsaturated polyester resin. 0.1 to 1 mm of colored silica sand and crushed glass particles were sprayed as a molding material for the decorative layer 12 to a thickness of about 2 mm. A pre-heated cement asbestos board coated with a polyester resin was set as a molding material for the base material 13 on the upper surface thereof, and a surface pressure of 10 kg / cm ² , 1
The artificial stone 10 was obtained by hot pressing at 70 ° C. for 15 minutes. Here, the intergranular gap of the plate-like body made of the inorganic granular material coated with the above-described resin material is 33% by volume. FIG. 3 shows the appearance of the artificial stone 10 thus obtained and the results of the surface test specified in the Ministry of Construction Notification No. 1231.
FIG. 4 shows an exhaust temperature curve of the surface test, and FIG. 5 shows a smoke coefficient curve of the surface test.

Example 2 In this example, a transparent vinyl chloride resin sheet having a thickness of 0.1 mm was set as a molding material for the surface layer 11, and a thermosetting acrylic resin was added thereto so that the thermosetting acrylic resin was 5% by weight. Particle size 0.1 coated with resin
ケ イ 2 mm of colored silica sand, colored cold water stone, and glass frit were sprayed to a thickness of about 2 mm as a molding material for the decorative layer 12. On its upper surface, a foamed glass lightweight aggregate (particle diameter: 0.1 to 2.0 mm) coated with phenolic resin so as to be 5% by weight of phenolic resin and a 40 mm long glass chopped impregnated with 20% by weight of phenolic resin. 8 with the strand
It was sprayed to a thickness of about mm to obtain a molding material for the base material layer 13. In this state, after hot-pressing at a surface pressure of 10 kg / cm ² at 170 ° C. for 15 minutes, the surface was ground, painted and polished with a polyester resin, and an artificial stone 10 having a 90 μm coating film was obtained. Here, the intergranular gap of the plate-like body made of the inorganic granular material coated with the above-described resin material is 31% by volume. FIG. 3 shows the appearance of the artificial stone 10 and the results of a surface test defined in the Ministry of Construction Notification No. 1231.

Example 3 Silicon-modified acrylic resin coated with silicon-modified acrylic resin at 3% by weight has a particle size of 0.1 to 0.1%.
1 mm glass particles and porcelain ground particles, particle size 0.1-2
After the colored mica particles having a thickness of 2 mm were sprayed as a molding material for the decorative layer 12 to a thickness of about 2 mm, white colored silica sand coated with the same resin was sprayed as a decorative hiding layer for about 0.5 mm. A glass cloth impregnated with 30% phenolic resin (basis weight = 86 g / m ² ) was set thereon as a reinforcement, and a lightweight glass foam aggregate (particles) coated with phenolic resin so as to be 5% by weight of phenolic resin was set thereon. Diameter 0.1 ~
2 mm) to a layer thickness of about 10 mm, and further set a reinforcing glass cloth thereon to set a surface thickness of 5 kg / cm ² , 180 ° C., and 2 ° C.
It was hot pressed for 0 minutes. Thereafter, a transparent sealing coating was applied to the surface, and after grinding, a coating film of 90 μm was formed by polyester UV coating. Here, the intergranular gap of the plate-like body made of the inorganic granular material coated with the resin material is 25% by volume. Appearance of this artificial stone 10 and Notification 1 of Ministry of Construction
FIG. 3 shows the results of the surface test specified in No. 231.

Example 4 In this example, a transparent unsaturated polyester equivalent to 100 g / m ² was applied to a surface plate in advance as a surface layer 11, and a polyester resin 3 wt. % Glass particles having a particle size of 0.1 to 1 mm coated with a polyester resin and ground ceramic particles having a particle size of 0.1 to 2 mm were sprayed together with glass chopped strands impregnated with 20% polyester to a thickness of about 5 mm. Next, hot-pressing was performed at 170 ° C. for 15 minutes at a surface thickness of 10 kg / cm ² , and then the finished artificial stone 10 was obtained by grinding and polishing the surface. Here, the intergranular space of the plate-like body made of the inorganic granular material coated with the resin material is 24% by volume. FIG. 3 shows the appearance of the artificial stone 10 and the results of a surface test defined in the Ministry of Construction Notification No. 1231.

Example 5 Glass particles having a particle size of 0.1 to 1 mm coated with a thermosetting acrylic resin so as to be 3% by weight of the thermosetting acrylic resin as the decorative layer 12 and a glass particle having a particle size of 0.1 to 2 mm. Spray ceramic sintered particles to a thickness equivalent to 10mm, surface thickness 10kg
/ cm ² at 200 ° C. for 5 minutes. Thereafter, a transparent PMMA sheet (0.2 mm thick) was bonded to the surface of the molded body at room temperature with a vinyl urethane resin adhesive, and a mirror surface was obtained to obtain an artificial stone 10. Here, the intergranular gap of the plate-like body made of the inorganic granular material coated with the resin material is 29% by volume. FIG. 3 shows the appearance of the artificial stone 10 and the results of a surface test defined in the Ministry of Construction Notification No. 1231.
Shown in

Example 6 In this example, a glass nonwoven fabric (basis weight = 100 g / cm ² ) was set on a plate as a surface layer 11 and impregnated with a thermosetting acrylic resin (impregnation amount 150 g / m ² ). Glass particles having a particle size of 0.1 to 1 mm coated with a thermosetting acrylic resin so as to be 3% by weight of the thermosetting acrylic resin forming the decorative layer 12 thereon and natural particles having a particle size of 0.1 to 3 mm The marble particles were sprayed to a thickness of about 2 mm. Next, the base material layer 13
A 40 mm long glass chopped strand coated with a phenolic resin so as to have a phenolic resin content of 20% by weight, and a lightweight foamed glass having a particle size of 0.1 to 2.0 mm coated with a phenolic resin content of 5% by weight A blend of the aggregates at a weight ratio of 1: 9 was sprayed to a layer thickness of about 7 mm. And a surface thickness of 10 kg / cm ² , 180 ° C., 15
Min, and then the surface was ground to form a finished surface. Here, the intergranular gap of the plate-like body made of the inorganic granular material coated with the resin material is 28% by volume. FIG. 3 shows the appearance of the artificial stone 10 and the results of a surface test defined in the Ministry of Construction Notification No. 1231.

Comparative Example 1 100 parts by weight of unsaturated polyester, 340 aluminum hydroxide
Parts by weight, 40 parts by weight of colored silica sand, 40 parts by weight of colored mica, and 20 parts by weight of glass fiber having a length of 3 mm are kneaded with a kneader, and an additive such as MgO is added, and then 1 part by weight of a curing agent Perbutyl Z is added. Surface pressure 100 kg / cm ² , 140 ° C, 5
A 2 mm thick, 18.5% organic compact was obtained by hot-pressing for 1 minute and bonded to a cement asbestos board with a urethane adhesive. FIG. 3 shows the appearance of the artificial stone thus obtained and the results of the surface test defined in Ministry of Construction Notification No. 1231.
FIG. 4 shows an exhaust temperature curve of the surface test, and FIG. 5 shows a smoke coefficient curve of the surface test.

Comparative Example 2 100 parts by weight of unsaturated polyester resin, colored silica sand 20
After kneading 0 parts by weight with a kneader and adding an additive such as MgO, 1 part by weight of a hardening agent perbutyl was added, and a surface pressure of 10 parts was added.
It was hot-pressed at 0 Kg / cm ² at 140 ° C. for 5 minutes to obtain a molded product having a thickness of 2 mm. The molded body was placed on a platen, and a glass chopped strand of 40 mm in length coated with phenol resin so as to have a phenolic resin content of 20% by weight, and a phenol resin was coated so as to have a phenolic resin content of 5% by weight. A mixture of the obtained lightweight glass foam aggregate having a particle size of 0.1 to 2.0 mm and a weight ratio of 1: 9 is sprayed with a thickness of about 8 mm. Thereafter, hot pressing was performed under the same conditions as in Example 2. FIG. 3 shows the appearance, strength, and results of a surface test specified in the Ministry of Construction Notification No. 1231.

As shown in FIG.
The artificial stone of No. 6 is more glaring than the artificial stones of Comparative Examples 1 and 2, and has excellent appearance. In addition, both the exhaust temperature and the smoke emission coefficient, which are the results of the surface test, show favorable values.

[0037]

[0038]

Since the present invention is constructed and operates as described above, according to the present invention, it is possible to obtain a structure having excellent fire protection by reducing the amount of resin used in addition to obtaining an expected decorative appearance. In addition to achieving a certain level of strength and maintaining a heat insulating effect while reducing the overall weight, it is also possible to manufacture at a low cost by expanding the selection range of manufacturing methods. It is possible to provide an artificial stone exhibiting an unprecedented excellent effect of producing an artificial stone and a method for producing the same. Furthermore, in the present invention, since a structure having a gap S inside is employed, a resin containing a volatile component such as a solvent-based or water-based resin can be employed as a resin to be used,
It is also expected to provide an artificial stone capable of expressing a wide variety of appearances by expanding the range of choice of molding materials.

[Brief description of the drawings]

FIG. 1 is a sectional view showing an embodiment of an artificial stone according to the present invention.

FIG. 2 is a sectional view of a main part in the embodiment.

FIG. 3 is a diagram showing experimental results of each example and a comparative example.

FIG. 4 is a diagram showing a comparison of exhaust temperatures between Example 6 and Comparative Example 1.

FIG. 5 is a diagram showing a comparison of a smoke generation coefficient between Example 6 and Comparative Example 1.

FIG. 6 is a cross-sectional view showing an example of a conventional artificial stone.

[Explanation of symbols]

Reference numeral 10: artificial stone, 11: surface layer, 12: decorative layer, 12A: inorganic granular material, 13: base material layer, S
... intergranular space.

──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. ⁶ identification symbol FI C04B 32/02 C04B 32/02 Z 38/00 302 38/00 302C (58) Fields surveyed (Int.Cl. ⁶ , DB name ) C04B 32/00

Claims (7)

(57) [Claims] An inorganic granular material coated with a resin material having a light-transmitting property is joined by point contact to form a plate having a predetermined intergranular gap, and at least one surface of the plate is transparent. An artificial stone comprising a light-emitting surface layer. 2. An inorganic granular material coated with a translucent resin material is point-contact-coupled to each other to form a plate having a predetermined intergranular gap, and one surface of the plate has a light-transmitting surface. An artificial stone comprising a surface layer having properties and a base material layer provided on the other surface. 3. A resin material for coating the inorganic particulate material is artificial claim 1 or 2 wherein 1 to 20 wt% of the plate of inorganic granules coated with a resin material stone. 4. The intergranular gap of a plate made of an inorganic particle coated with a resin material is 10 to
4. The composition according to claim 1 , wherein the content is 50% by volume.
The artificial stone described. 5. After setting a light-transmitting surface layer molding material, an inorganic particulate material coated with a light-transmitting resin material is sprayed on one surface of the surface layer molding material, and then the inorganic particle material is coated. A method for producing an artificial stone, comprising subjecting a surface layer forming material and an inorganic granular material to hot press molding so as to enable point contact bonding while maintaining a predetermined amount of intergranular space of the body. 6. The method for producing an artificial stone according to claim 5, wherein after the inorganic granular material is sprayed, a base material is further laminated and subjected to hot press molding. 7. A base material which is formed by laminating an inorganic granular material coated with a resin material having a light-transmitting property and a base material forming material, and capable of performing point contact bonding while maintaining a predetermined amount of intergranular space of the inorganic granular material. A method for producing an artificial stone, characterized in that a layer forming material and an inorganic granular material are hot-press-molded, and thereafter, a light-transmitting surface layer is formed on the surface of the inorganic granular material.