JP2937594B2 - Molding method of artificial stone - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for forming an artificial polyester resin-based artificial stone having a pattern such as a stone pattern or a multicolored color.

[0002]

2. Description of the Related Art Unsaturated polyester resin compositions, unsaturated polyester resin SMC (sheet molding compound) compositions or BMC (bulk molding compound) compositions, epoxy resin compositions or acrylic resin compositions. Artificial stones are formed by using such stones, and these artificial stones are widely used in the fields of vanities, bathtubs, counters, and interior and exterior materials for buildings.

[0003] Among them, the artificial stone based on unsaturated polyester resin is shown in FIGS. 3 to 6. First, a clear gel coat is applied to form a clear gel coat layer 1.
Next, a marble-like layer 3 is formed by injecting a colorless or artificial composition for coloring 2 ′ such as colorless or white (FIG. 3) or onyx tone (FIGS. 4 and 5) and injecting a transparent composition. . In this case, the coloring 2 'is obtained by coloring the composition for artificial stone with an appropriate color toner and manually applying it to the clear gel coat layer 1, or roughly mixing (not sufficiently mixing) the color toner with the composition for artificial stone. In this case, the clear gel coat layer 1 is poured. As shown in FIG. 6, one or two or more types of fine stones each having a different color are mixed with the composition for artificial stone to form a stone-like fine stone layer 3 '.
Are formed. Reference numeral 6 denotes a backup layer formed by FRP.

[0004] These artificial stones A 'have the required performance in use, and their patterns are also accepted in the market as useful building materials having a texture and the demand for them tends to further increase.

[0005]

However, in the conventional artificial stone molding, special equipment and skills are required for patterning, the method of patterning is not good, the reproducibility is not good, and air bubbles are apt to enter. There is a problem in that the appearance of the stone surface is impaired, and when it is used in a bathtub, problems tend to occur in hot water resistance. In recent years, the emergence of artificial stones with new patterns has been desired from the needs of diversifying customers,
At present, there is a limitation in production technology or technology, and only artificial stone having a pattern shown in FIGS. 3 to 6 is provided.

The present invention has been made in view of the above circumstances, and an object of the present invention is to provide a method for forming an artificial stone having an unprecedented stone pattern or multicolored pattern.

[0007]

According to a first aspect of the present invention, an unsaturated polyester resin-based clear gel coat is applied in a mold to form a clear gel coat layer 1, and then a colored coating material is sprayed thereon. Forming a small patchy pattern layer 2 exhibiting a stone-like or multicolored pattern, and then injecting a transparent unsaturated polyester resin-based artificial stone composition to form a marble-like layer 3; The second invention is characterized in that a clear gel coat based on an unsaturated polyester resin is applied in a mold to form a clear gel coat layer 1, and then a colored coating material is sprayed to give a stone-like or multi-colored material. A small patchy pattern layer 2 having a colored pattern is formed, and thereafter, a colored gel coat serving as a base layer color is applied to form a colored gel coat layer 4, and then the FRP layer 5 is formed by laminating FRP. It is characterized in the formation, in which above problems have been solved by this arrangement.

[0008]

According to the first aspect of the present invention, since the small patch-like pattern layer 2 having a stone-grained and multicolored pattern is formed by an unsaturated polyester resin-based coloring material or coloring paint, the surface of the artificial stone A is formed. Is provided with a marble-like layer 3 which is dotted with a stone pattern or a multicolored pattern and has a deep and rich material feeling on the back surface thereof so that a beautiful appearance can be obtained. According to the second aspect, the colored gel coat layer 4 is disposed on the back surface of the small mottled pattern layer 2 to give a unique and beautiful appearance.

Hereinafter, the present invention will be described in detail with reference to the accompanying drawings. First, an unsaturated polyester resin-based clear gel coat is applied in a mold by a spray gun to form a clear gel coat layer 1. Next, a coating material such as a coloring material or a coloring paint is spray-painted to form a small patchy pattern layer 2 having a stone-like or multicolored pattern. The coating material used for forming the small mottled pattern layer 2 may be any material having a predetermined viscosity and not interfering with coating by a normal spray gun. However, in the necessity of satisfying various properties required for final artificial stone, and in the fleshing and back-up molding of the marble-like layer 3 in the next step, if the layer exhibiting a stone-grained or multicolored pattern is insufficiently dried or hardened. The pattern will collapse, and workability must be considered. Accordingly, as a coating material, an unsaturated polyester resin whose vehicle is a thermosetting resin, a two-component urethane resin, a two-component fluorine resin, a two-component silicon resin, or the like is used. Among them, the unsaturated polyester resin is preferable because the adhesion to the clear gel coat layer 1 and the marble-like layer 2 is improved.

[0010] This coating material uses a usual gel coating spray gun and the gauge pressure at the time of coating is 0.1 to 0.5 kg.
/ Cm ² and spraying. This coating material can be arbitrarily selected as one type or two or more types of vehicle type or color type. At this time, the following tendencies are observed in the type of the coating material, the fine porphyritic tone, and the multicolored pattern formed by the workability. Pattern size Large Small Coating material viscosity High Low Coating film thickness Thick Thin Spray gun nozzle diameter Large Small Air pressure (atomization pressure) Low High Pressure applied to coating material (discharge rate) High (high) Low (low) Next, in the first invention, as shown in FIG. 1, after the coating material is cured, an unsaturated polyester resin-based artificial stone composition having a transparent feeling is injected to form the marble-like layer 3. The composition for artificial stone includes, for example, 100 parts by weight of an unsaturated polyester resin, 180 parts by weight of aluminum hydroxide powder, 1 part by weight of a color toner, 0.2 parts by weight of an additive, and 1.0 part by weight of a curing catalyst. Is mentioned.

The pouring of the composition for artificial stone can be carried out as it is if the molded product is a flat plate, but in many cases, after defoaming the composition, the composition is injected under pressure into a closed mold. Adopt operation. In this case, the artificial stone A has a beautiful appearance in which a small patchy pattern layer 2 having a grain pattern or a multicolored pattern is scattered on the surface and a marble-like layer 3 having a deep texture is arranged on the back surface. is there.

A backup layer 6 can be formed by laminating FRP on the marble-like layer 3. In the second invention, after forming the small mottled pattern layer 2, as shown in FIG. 2, a colored gel coat serving as a base layer color is applied to form a colored gel coat layer 4, and then an unsaturated polyester resin and glass This is to form the FRP layer 5 by laminating and molding an FRP made of a mat.

The artificial stone A thus obtained has a unique and beautiful appearance in which a small patch-like pattern layer 2 is scattered and a colored gel coat layer 4 serving as a base color is disposed on the back surface thereof. . Next, examples of the present invention will be described specifically. In the following, "parts" indicates parts by weight. Example 1 A clear gel coat ¹⁾ was applied in a mold and cured to form a clear gel coat layer. An unsaturated polyester resin composition having the following composition was used as a coating material exhibiting a stone pattern or a multicolored pattern. Coating material composition A B Clear gel coat ¹⁾ 100 parts 100 parts Black toner ²⁾ 1 part-White toner ³⁾ -1 part 6% Co promoter ⁴⁾ 0.5 parts 0.5 parts 1) Clear gel coat "DK- 306 "(manufactured by Taitai Kako Co., Ltd., type B viscometer 6 rpm 11000 cps 6
2) Polymer 9315 (unsaturated polyester resin, manufactured by Takeda Pharmaceutical Co., Ltd.) / Black toner composed of carbon black = 80/20 (weight ratio) 3) Polymer 9315 / titanium oxide = 50/50 (weight ratio) 4) 6% cobalt naphthenate (manufactured by Toei Kako Co., Ltd.) First, a 1% curing catalyst MEKPO was added to the coating material composition A.
(“Permec M”, manufactured by Akzo Chemical Co., Ltd.), and sprayed on the clear gel coat layer at an air pressure of 0.2 kg / cm ² . Next, the curing catalyst M is added to the coating material composition B.
1% of EKP was added and sprayed under the same conditions. In this case, the spray blow does not cover the entire surface of the object to be coated, but sprays so that the applied material is appropriately placed.

Next, the following composition is applied on the coating pattern.
The artificial stone composition was poured and cured. Composition for artificial stone Unsaturated polyester resin ("Polymer 3308" (orthophthalic resin) manufactured by Takeda Pharmaceutical Co., Ltd.) 100 parts Glass frit ("M-10S" manufactured by Nippon Fellow Co., Ltd.) 100 parts Aluminum hydroxide Powder ("Heidilite H100" manufactured by Showa Denko KK) 100 parts Additive (Byk-A510 manufactured by BYK Japan KK) 0.3 part Color toner ("DT toner CH-193") 1 part Curing catalyst ( "Kayamec M" (MEKPO) Kayaku Akzo) 1 part Hardening accelerator ("P-110B" (cobalt-based accelerator) manufactured by Takeda Pharmaceutical Co., Ltd.) 0.1 part Black and white porphyry stones
The eyes are dotted and the back has a rich and rich material
It has a beautiful appearance with a marble-like layer. (Example 2) The same clear gel coat as in Example 1 was placed in a mold.
Layer was formed. Stone-tone, colored with multicolored patterns
As a coating material, a two-component urethane resin coating having the following composition was used.
The starting composition was used.  Coating material composition C D Next Archon^Five)Main agent Red 80 parts-NEXTALCON Main agent green-80 parts NEXTALCON Hardener 20 parts 20 partsNextalcon Thinner 20 parts 20 parts 5) Next arcon contains scaly aluminum powder
Urethane resin-based hammertone paint (Taitai Kako Co., Ltd.)
The viscosity of Ford cup of all formulations was about 2 for both compositions C and D.
5 seconds. First, the composition C was supplied with an air pressure of 0.3 kg / cm.
^Two Spray on the clear gel coat layer cured by
went. Then, leave it at 25 ° C for about 10 minutes.
The composition D was sprayed under the same conditions. This place
Spraying does not cover the entire surface of the work
Sprinkle so that the coating material is placed. Always after spraying
6 hours at 60 ° C or 1 hour at 60 ° C
gave.

Thereafter, the same artificial stone composition as in Example 1 was poured and cured. The artificial stone produced in this way is dotted with small patches having red and green contrast and silvery shine by aluminum powder on the surface, and a deep, rich material-like marble-like layer on the back surface. It had a beautiful appearance. (Example 3) The same clear gel coat layer as in Example 1 was formed in a mold. As a coating material exhibiting a stone pattern and a multicolored pattern, a two-component fluororesin-based coating composition having the following composition was used. Coating material composition EF Ceracoat ⁶⁾ Main ingredient Yellow 80 parts-Ceracoat Main ingredient Ivory color-80 parts Ceracoat Hardener 20 parts 20 parts Ceracoat Thinner 20 parts 20 parts 6) Ceracoat is a fluororesin hammer containing scale-like aluminum powder Tone paint (manufactured by Taitai Kako Co., Ltd.) The Ford cup viscosity of all formulations is about 20 seconds for both E and F. First, the composition E was sprayed on the clear gel coat cured at an air pressure of 0.1 kg / cm ² .
Next, the composition D was sprayed at 25 ° C. for about 10 minutes under the same conditions. In this case, the spray blow does not cover the entire surface of the object to be coated, but sprays so that the applied material is appropriately placed. After spraying, the mixture was left standing at normal temperature for 6 hours or heated at 60 ° C. for 1 hour.

Thereafter, the same artificial stone composition as in Example 1 was poured and cured. The artificial stone manufactured in this way is dotted with small patches of yellow and ivory harmony and silvery shine due to aluminum powder on the surface, and has a deep and rich marble-like layer on the back surface. Had a beautiful appearance. (Example 4) After spraying the compositions A and B in the same manner as in Example 1, the gray gel coat ("DK-306GR"
(Y, manufactured by Taitai Kako Co., Ltd.) 100 parts of MEKPO and 1 part of MEKPO were spray-sprayed at an air pressure of 4 kg / cm ² to form a colored gel coat layer of about 400 μm.

After the colored gel coat layer is cured, the unsaturated gel
Reester resin composition ("Polymer 8225" Takeda Pharmaceutical Co., Ltd.)
Shin Kogyo Co., Ltd.) and 3-ply $ 450 glass mat
Used to form an FRP layer. Molded in this way
Artificial stones are gray with dots behind black and white mottled grain pattern
It has a beautiful granite appearance with base colors. (Example 5) Composition C was densely scattered in the same manner as in Example 2.
0.3kg / cm air pressure ^Two Clear cured with
-After spraying on the gel coat layer, wet
 Almost the entire surface of the composition D was wet on similar conditions
The spray was sprayed to give a green color.

After spraying, the mixture was allowed to stand at room temperature for 6 hours or heated at 60 ° C. for 1 hour.
The FRP layer was laminated in the same manner as described above. The artificial stone thus formed exhibited a beautiful contrast pattern in which silver-red fine platy patterns were arranged on a silver-green background. (Example 6) Compositions E and F were sprayed in the same manner as in Example 3 and then allowed to stand at room temperature for 6 hours or at 60 ° C for 1 hour.
After heating for a time, a white gel coat ("DK-
306 WHT ”manufactured by Taitai Kako Co., Ltd.) 100 parts and MEK
Colored gel coat consisting of 1 part of PO is air pressure 4 kg / cm
² was sprayed to form a colored gel coat layer of about 400 μm.

Next, an FRP layer was laminated in the same manner as in Example 4. The artificial stone molded in this way is yellow on a white background,
It has a mosaic appearance with a harmonious ivory color.

[0020]

According to the present invention, a peculiar pattern having a peculiar sense of quality, which could not be exhibited conventionally, is formed by spraying a small patchy pattern exhibiting a stone pattern and a multicolored pattern.
Can be easily performed with good reproducibility . In addition, the artificial stone obtained by patterning according to the present invention has good hot water resistance since no aggregate is blended in the coating material, and also has improved cracks on the surface layer, and It can be used for bathtubs, dressing tables, interior and exterior materials for buildings, etc. with unconventional designs, and it will also expand the design and application.

[Brief description of the drawings]

FIG. 1 is a cross-sectional view showing an example of an artificial stone manufactured by the method of the first invention of the present invention.

FIG. 2 is a cross-sectional view showing an example of an artificial stone manufactured by the method of the second invention of the present invention.

FIG. 3 is a cross-sectional view illustrating an example of an artificial stone manufactured by a conventional method.

FIG. 4 is a sectional view showing another example of the artificial stone according to the above.

FIG. 5 is a sectional view showing still another example of the artificial stone according to the above.

FIG. 6 is a sectional view showing still another example of the artificial stone according to the above.

[Explanation of symbols]

 A Artificial stone 1 Clear gel coat layer 2 Small patchy pattern layer 3 Marble-like layer 4 Colored gel coat layer 5 FRP layer 6 Backup layer

──────────────────────────────────────────────────続 き Continued on the front page (72) Inventor Toshifumi Okuno 1-17-38 Nishiyasu, Ibaraki-shi, Osaka (72) Inventor Yoshinori Okochi 3-11-2 Torikai Nishi, Settsu-shi, Osaka Ota Chemical Co., Ltd. (56) References JP-A-58-116124 (JP, A) JP-A-61-127312 (JP, A) JP-A-5-104548 (JP, A) JP-B-50-3104 (JP, B1) (58) Field surveyed (Int. Cl. ⁶ , DB name) B29C 39/02 B29C 39/10-39/12 B29C 39/22-39/24

Claims (4)

(57) [Claims] An unsaturated polyester resin-based clear gel coat is formed in a mold to form a clear gel coat layer, and then a colored coating material is sprayed on the mold to produce a small patchy pattern having a stone-like or multicolored pattern. A method for forming an artificial stone, comprising: forming a layer, and thereafter injecting a transparent unsaturated polyester resin-based composition for artificial stone to form a marble-like layer. 2. The method according to claim 1, wherein the coating material is an unsaturated polyester resin composition. 3. A clear gel coat of an unsaturated polyester resin is applied in a mold to form a clear gel coat layer, and then a colored coating material is sprayed thereon to give a small patch-like pattern having a stone-like or multicolored pattern. After forming a layer, a colored gel coat layer serving as a base layer color is applied to form a colored gel coat layer.
A method for forming artificial stone, comprising forming a layer. 4. The method according to claim 3, wherein the coating material is an unsaturated polyester resin composition.