JP5457295B2 - Manufacturing method of natural grain surface treatment material - Google Patents

Description

  The present invention relates to a method for producing a natural grain facing material.

  Reinforcement plates such as calcium silicate boards, gypsum boards, and plywood use interior face materials in which surface materials such as inorganic decorative boards, natural stones, artificial stones made of polyester resin, acrylic resin, etc. are attached. ing. Among them, a face material using natural stone as a surface material has a large surface hardness, excellent discoloration, and expresses a high-grade appearance, but is heavy and difficult to handle. Therefore, as an improved handling property, a decorative material in which a porous natural stone such as lava is stuck on the surface of a flexible decorative base material such as plastic, FRP, or cloth has been proposed (for example, patent document). 1). The decorative natural porous natural stone is generally a pulverized product, and the crushed product and the decorative base material are fixed (attached) by applying an adhesive to the pulverized product or the decorative base material. Yes.

JP-A-11-170798

  The decorative material described in Patent Document 1 is thin and lightweight, and is excellent in handleability. However, in order to obtain a texture of natural stone, it is necessary that the pulverized product of porous natural stone is uniformly arranged on the flexible decorative base material. It is difficult to fix firmly so that it does not detach from. In addition, it has been pointed out that the porous natural stone on the surface of the decorative base material is easily soiled and easily damaged.

  The present invention has been made in view of the circumstances as described above, and is a natural stone-grained surface material that can easily obtain a light-weight face material that has a natural stone appearance and has reduced scratches and dirt on the surface. It is an object to provide a manufacturing method.

  In the method for producing a natural stone textured material according to the present invention, the transparent liquid resin applied to the surface of a block of natural stone that peels and forms a plate shape is cured to form a transparent resin layer integrally with the block. By separating the plate-like natural stone from the block stone, a face material in which the plate-like natural stone is integrated on the back side of the transparent resin layer is obtained.

  In this method for producing a natural grain texture material, the transparent liquid resin is preferably an epoxy resin, an acrylic resin, or an unsaturated polyester resin.

  Moreover, in this method for producing a natural stone textured material, it is preferable that the plate-like natural stone is peeled off from the block stone after the start point of peeling is put on the side end surface of the block stone over the entire circumference.

  ADVANTAGE OF THE INVENTION According to this invention, the lightweight face material which has the appearance of a natural stone and reduced the damage | wound of a surface and dirt can be obtained simply.

It is a schematic diagram which shows one Embodiment of the manufacturing method of the natural grain tone surface material of this invention.

  Hereinafter, embodiments of the present invention will be described with reference to the drawings.

  In this embodiment, as shown in FIG. 1, a transparent liquid resin 3 is applied to the surface 2 c of the natural stone block 2 and cured to integrate the transparent resin layer 4 made of the transparent liquid resin 3 integrally with the natural stone block 2. After the formation, the surface side portion 2a (the upper portion of the block 2 in FIG. 1) of the block 2 is peeled off. The natural stone-like surface comprising the transparent resin layer 4 and the plate-like natural stone 5 is separated from the block 2 in a state where the plate-like natural stone 5 is integrated with the back surface side of the transparent resin layer 4 by peeling off the surface side portion 2a. Material 1 is obtained.

  In this embodiment, the natural stone block 2 as a raw material is a stone that peels and forms a plate shape. As this natural stone, a stone made of sand particles such as sandstone is relatively difficult to peel off, and therefore, a stratified stone, a stone having a peeling property, etc., such as basho stone, is preferable. The natural stone block 2 may be cut into an appropriate shape according to the arrangement of the face material 1 to be obtained. For example, in FIG. 1, it is cut into a rectangular shape in plan view, whereby a plurality of face materials 1 can be regularly arranged.

  The thickness of the natural stone block 2 is not particularly limited as long as the plate-like natural stone 5 can be formed. The plate-like natural stone 5 has, for example, a thickness of 1 mm or more, and the lump stone 2 preferably has a thickness of, for example, 10 mm or more so that the plate-like natural stone 5 is not chipped or cracked by peeling.

  As the transparent liquid resin 3 applied to the surface 2c of the natural stone block 2, various conventionally known liquid resins having transparency can be used. For example, thermosetting resins such as urethane resins, acrylic resins, epoxy resins, and unsaturated polyester resins, and thermoplastic resins such as polyolefin resins and vinyl chloride resins can be used. In particular, thermosetting resins have good functionality such as durability of cured resin, and acrylic resins, epoxy resins, and unsaturated polyester resins have a good balance between functionality and price, and are preferably used. . The transparent liquid resin 3 may contain glass fibers in order to increase the strength.

  Examples of the curing mode of the thermosetting resin include thermosetting, moisture reaction curing, and ionizing radiation curing such as ultraviolet rays and electron beams.

  The transparent resin layer 4 obtained by curing the transparent liquid resin 3 preferably has a thickness of 1 mm or more. As a result, the natural tone of the natural stone becomes obvious, and it is possible to give an external appearance rich in three-dimensional effect and with a sense of depth. Further, when the face material 1 is used, it is effective in preventing damage to the plate-like natural stone 5 and preventing dirt, and it is possible to reduce the damage on the surface of the face material 1 and adhesion of dirt.

  The upper limit of the thickness of the transparent resin layer 4 is not particularly limited as long as the natural tone of the natural stone is manifested and a three-dimensional appearance and a depth appearance are developed. If the transparent resin layer 4 becomes too thick, the face material 1 becomes heavy and the handleability may be lowered, and the cost is increased.

  The surface of the transparent resin layer 4 is preferably a smooth surface, but may have some unevenness. In addition, you may make it form a big wavy shape etc. intentionally.

  The transparent resin layer 4 is preferably a single layer in order to develop a more three-dimensional appearance, but may be a plurality of layers (formed by laminating a plurality of single layers). In the case of a plurality of transparent resin layers, the thickness of each layer may be less than 1 mm as long as the thickness of the laminated state is 1 mm or more.

  The transparent resin layer 4 is formed integrally with the natural stone block 2. As a specific manufacturing method, for example, the above-described various transparent liquid resins 3 are applied to the surface 2c of the block 2 and the resin surface is smooth and heat curing, moisture reaction curing, ultraviolet rays, The transparent resin layer 4 is fixed to the surface 2c of the block 2 by being cured by a method such as ionizing radiation curing such as an electron beam. You may perform a hot-pressure process. When the transparent resin layer 4 has a plurality of layers, the application of the transparent liquid resin 3 and subsequent curing may be repeated a plurality of times. The application method may be any method as long as it can be applied evenly without air bubbles or foreign matters entering the surface 2c of the block 2 and is not particularly limited. For example, as shown in FIG. 1, a method is used in which a mold 6 is placed on the surface 2 c of a natural stone block 2 and applied by injecting a transparent liquid resin 3 into the mold 6. After applying the transparent liquid resin 3 in the mold 6, the transparent liquid resin 3 is cured by a method such as thermosetting, moisture reaction curing, ionizing radiation curing, and then the mold 6 is removed and the surface 2 c of the block 2 The transparent resin layer 4 is formed.

  As a coating method of the transparent liquid resin 3, methods such as a roll coater, a flow coater, and a spray can be employed besides the above-described coating method.

  Thus, in this embodiment, since the transparent resin layer 4 and the block 2 are integrally formed by applying and hardening the transparent liquid resin 3 on the surface 2c of the block 2 of natural stone, an adhesive, etc. Therefore, it is possible to manufacture at a low cost, for example, by eliminating the step of fixing the transparent resin layer 4 and the block 2 using the. Further, even when the surface 2c of the natural stone block 2 has unevenness, the transparent liquid resin 3 can be applied along the uneven shape, and the transparent resin layer 4 is applied to the surface 2c of the natural stone block 2 having unevenness. Can be easily and reliably formed.

  In this embodiment, after forming the transparent resin layer 4 on the surface 2c of the natural stone block 2, the surface side portion 2a of the block 2 on which the transparent resin layer 4 is formed is peeled off. As this peeling method, for example, a separation starting point 7 (cut) is made by using a chisel or the like at a portion of the side end face 2b of the block 2 that is a predetermined thickness away from the transparent resin layer 4, and the transparent resin layer in the vicinity thereof. 4 or a method of pulling (lifting) the surface side portion 2 a away from the surface 2 c of the block 2. As another method, a method of simply driving a flea or the like into the side end surface 2b of the block 2 can be employed. Thereby, the surface side portion 2a having a predetermined thickness is peeled off, and the face material 1 in which the transparent resin layer 4 is formed on the surface of the plate-like natural stone 5 is obtained.

  When the starting point 7 is put on the side end face 2b of the block 2 above, it may be put only in the corner portion, but in order to keep the thickness of the surface side portion 2a to be peeled constant, the entire side end face 2b of the block 2 is placed on the side end face 2b. It is preferable to put the starting point 7 over the circumference. After putting the starting point 7 over the entire circumference, the face material 1 having the plate-like natural stone 2 having a uniform thickness is obtained by lifting and peeling off the surface side portion 2a.

  The remaining block 2 after the surface-side portion 2 a is peeled off is used as a raw material for a new face material 1.

  As described above, the face material 1 is easily obtained by a simple method in which the surface side portion 2a of the natural stone block 2 is peeled off in a state where the transparent resin layer 4 obtained by curing the transparent liquid resin 3 is formed on the surface 2c. be able to.

  Since the obtained face material 1 has the transparent resin layer 4 formed on the surface of the plate-like natural stone 5, it is effective in preventing the plate-like natural stone 5 from being scratched and preventing dirt. Dirt adhesion can be reduced. The transparent resin layer 4 is effective for reducing the weight of the face material 1. Thereby, handling of the face material 1 becomes easy, restrictions on the installation method are reduced, and the construction cost can be suppressed. It can easily cope with a three-dimensional solid shape. When the thickness of the transparent resin layer 4 is 1 mm or more, the texture of the plate-like natural stone 5 is manifested, and a natural stone-like appearance with a rich three-dimensional effect and a sense of depth is effectively expressed.

  Such a face material 1 can be used as a face material for flooring, walls, ceilings, doors and the like as a member for housing and building materials, and as a face material for watering equipment.

  While the present invention has been described based on the embodiments, the present invention is not limited to the above-described embodiments, and various modifications can be made without departing from the scope of the invention.

DESCRIPTION OF SYMBOLS 1 Face material 2 Block stone 2a Surface side part 2b Side end surface 2c Surface 3 Transparent liquid resin 4 Transparent resin layer 5 Plate-like natural stone 7 Starting point

Claims (3)

  By curing the transparent liquid resin applied to the surface of the natural stone block that is peeled and forming a transparent resin layer integrally with the block, and then peeling off the surface side portion of the block A method for producing a natural-grained surface material, comprising obtaining a face material in which a plate-like natural stone is integrated on the back side of the transparent resin layer.   The said transparent liquid resin is an epoxy resin, an acrylic resin, or an unsaturated polyester resin, The manufacturing method of the natural grain tone surface material of Claim 1 characterized by the above-mentioned.   3. The method for producing a natural stone textured material according to claim 1, wherein after the starting point of peeling is put on the side end face of the block, the surface side portion of the block is peeled off.

Images