JP6664091B2 - Artificial marble and method for producing the same - Google Patents

Description

  The present invention relates to artificial marble and a method for producing the same.

  2. Description of the Related Art Conventionally, artificial marble having the same material, texture, and natural feeling as natural marble has been used in a wide range of building materials for houses and the like, kitchen counters, bathtubs, vanities, and the like. In the production of such artificial marble, patterning is performed, and the formed pattern gives an impression close to natural stone.

  In the patterning of artificial marble, for example, a method of using a natural material such as natural stone or mica or a crushed resin cured product as a pattern material, mixing with a base resin, and curing and molding is used. Also, a pattern is formed on the surface of the mold by attaching a droplet-shaped pattern material containing a resin material, a filler, a pigment, etc., and then the base resin is injected and cured to form a pattern on the surface of the molded product. Has been proposed (see Patent Document 1).

JP-A-3-193420

  However, since the pattern material of the above-mentioned pulverized material is usually uniformly dispersed in the base resin when mixed with the base resin, it is difficult to stably obtain a pattern with a natural texture. was there. In particular, there is still room for improvement from the viewpoint of imparting a sense of depth to the artificial marble by imparting a sense of transparency, improving the designability and improving the aesthetic value over other resin molded products.

  According to the method disclosed in Patent Document 1, a granite-like pattern with a large diameter can be expressed. However, the features of the pattern differ greatly between granite (granite) and marble due to differences in constituent components and the like. Therefore, it is insufficient as a patterning method for artificial marble. Further, the method of supplying a base resin after forming a pattern in a mold in advance as in Patent Literature 1 and performing molding is inferior in mass productivity and is not desirable in terms of production efficiency and production cost.

  The present invention has been made in view of the circumstances as described above, and has an artificial marble having a more natural color and a transparent patterned pattern, and having excellent productivity and a method for producing the same. The purpose is.

  In order to achieve the above object, the artificial marble of the present invention is formed by molding a resin composition containing a base resin having light transmittance and a pattern material having a different light transmittance or refractive index from the base resin. On one surface of the artificial marble, a plurality of coating films having different color tones from the base resin and the pattern material and being larger than the pattern material are formed.

  Further, the method for producing artificial marble of the present invention is characterized in that one surface of a molded article of a resin composition containing a base resin having light transmittance and a pattern material having a light transmittance or a refractive index different from that of the base resin. Further, a plurality of coating films having different color tones from the base resin and the pattern material and being larger than the pattern material are formed.

  ADVANTAGE OF THE INVENTION According to this invention, the artificial marble which has a more natural color and a transparent pattern, and is excellent in productivity, and its manufacturing method are provided.

It is the schematic which shows typically the structure of the artificial marble which concerns on embodiment of this invention, (a) is a perspective view, (b) is AA sectional drawing in (a).

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

  FIG. 1 is a schematic view schematically showing a configuration of an artificial marble according to an embodiment of the present invention. FIG. 1A is a perspective view, and FIG. 1B is a cross-sectional view taken along line AA in FIG. is there.

  The artificial marble 1 according to the present embodiment is formed by molding a resin composition containing a base resin 2 having light transmittance and a pattern material 3 having a different light transmittance or refractive index from the base resin 2. On one surface of the artificial marble 1, a plurality of coating films 4 having different color tones from the base resin 2 and the pattern material 3 and being larger than the pattern material 3 are formed.

  The base resin 2 is composed of a compound for a base resin in which a resin and other additives such as a filler, a curing agent, and a coloring agent are blended.

  The resin to be blended is not particularly limited as long as it is a resin having optical transparency, and can be appropriately selected according to the use of artificial marble and the like. For example, a thermosetting resin such as vinyl ester, unsaturated polyester, epoxy, acrylic, and melamine, and a thermoplastic resin such as polymethyl methacrylate, polycarbonate, and polyethylene terephthalate can be used. These may be used alone or in combination of two or more.

  The filler may be of various types, including those commonly used in the production of artificial marble. For example, inorganic substances such as calcium carbonate, glass powder, silica, and aluminum hydroxide may be mentioned, and may be subjected to a surface treatment or the like as necessary.

  The curing agent may be of various types including those generally used for the production of artificial marble, such as organic peroxides, for example, considering the half-life temperature according to the required molding temperature of artificial marble. Can be selected.

  Further, other additives such as a coloring agent can be appropriately selected in consideration of the use of the artificial marble and the like in consideration of not impairing the light transmittance of the base resin 2.

  The mixing ratio of the above components in the compound for base resin is not particularly limited as long as the base resin 2 has light transmittance.

  The pattern material 3, like the base resin 2, is composed of a pattern material compound in which a resin and other additives such as a filler, a curing agent, and a coloring agent are blended.

  The compounding of the above components in the pattern material compound is different from the compound for the base resin, and is appropriately adjusted by, for example, changing the type and the mixing ratio of the resin and the coloring agent used in the compound for the base resin.

The pattern material 3 thus prepared is appropriately ground or classified according to the required appearance of the artificial marble and the like, and the particle size is adjusted. In addition, the mixing ratio of the pattern material 3 to the base resin 2 in the resin composition is appropriately adjusted. The size of the pattern material 3 is preferably in the range of 5 mm ^{2 to 1} cm ² . As a result, the artificial marble 1 presents a pattern with a more natural texture.

  In the present embodiment, the base resin 2 and the pattern material 3 have different optical characteristics. More specifically, the base resin 2 and the pattern material 3 are different in light transmittance or refractive index.

  The light transmittance of the base resin 2 and the pattern material 3 can be, for example, the transmittance of light having a wavelength in a visible light region of 380 nm to 780 nm as an index. Also, the total light transmittance according to ASTM D1003 can be used.

  The refractive index of the base resin 2 and the pattern material 3 can be measured using an Abbe refractometer or a refractometer having performance equivalent to this.

  The degree of the difference in the optical properties between the base resin 2 and the pattern material 3 is not particularly limited as long as the effect of the present invention is not impaired, but the presence of the pattern material 3 can be recognized while maintaining the transparency of the artificial marble. The difference in light transmittance or refractive index is set from the viewpoint of excellent design.

  The coating film 4 is formed on one surface of the artificial marble 1. Preferably, as shown in FIG. 1, the coating film 4 is formed on the back surface 12 of the artificial marble 1 opposite to the design surface 11. Further, the coating film 4 has a different color tone from the base resin 2 and the pattern material 3 and is larger than the pattern material 3. Thereby, light incident from the surface of the artificial marble 1 (for example, the design surface 11) reaches the coating film 4 while transmitting and refracting the base resin 2 and the pattern material 3, and is further reflected and the like by the coating film 4. Thus, the design surface 11 of the artificial marble 1 presents a more natural color and a transparent pattern. In other words, due to the difference in light transmittance or refractive index between the base resin 2 and the pattern material 3, and the difference in color tone between the base resin 2, the pattern material 3, and the coating film 4, the artificial marble 1 has a more natural color. The pattern becomes transparent.

  The color tone of the coating film 4 may be one type or a combination of two or more types. For example, in the present embodiment, as shown in FIG. 1B, the color tone of the coating film 4a is different from that of the coating film 4b. As described above, the plurality of coating films 4 having different color tones increases the complexity of the color of the pattern of the artificial marble 1 and the like, and is expected to have an effect of further improving the appearance of the design surface 11 of the artificial marble 1. In addition, the color tone of the base resin 2, the pattern material 3, and the coating film 4 can be evaluated using a generally known index such as a Lab index.

  The thickness of the coating film 4 is not particularly limited, but can be appropriately adjusted according to the thickness of the artificial marble, the required appearance, and the like. Further, with respect to the plurality of coating films 4 formed on the artificial marble 1, the thickness of each coating film 4 may be constant, or may be different for each coating film 4, and the thickness of one coating film 4 may be one. It may be partially different.

  As a coating material for forming the coating film 4, a generally known configuration, for example, a mixture of a resin, a curing agent, a pigment, an additive, and a solvent can be used. In particular, in the present embodiment, the types of pigments such as inorganic pigments, organic pigments, and fluorescent pigments are appropriately selected according to the required appearance of artificial marble and the like, and the blending ratio is appropriately adjusted.

  In the present embodiment, it is preferable that the pattern material 3 has light transmittance. Thereby, the artificial marble 1 presents a lighter and more transparent pattern.

Further, in the present embodiment, it is preferred size of the coating film 4 is in the range of ^{1cm 2 ~1000cm} 2. Thereby, the coating film 4 straddles the plurality of pattern materials 3, and the artificial marble 1 presents a pattern with a more natural color.

  Further, it is preferable that the coating film 4 has an irregular shape. As a result, complex effects due to light transmission, refraction, reflection, and the like in the base resin 2, the pattern material 3, and the coating film 4 occur irregularly, and the artificial marble 1 exhibits a pattern with a more natural texture.

  Next, a method for manufacturing the artificial marble 1 according to the present embodiment will be described.

  First, a resin composition containing a base resin 2 having light transmittance and a pattern material 3 having a different light transmittance or refractive index from the base resin 2 is cast into a mold having a predetermined shape and cured to form a pattern. To obtain a molded body.

  The mold has a cavity corresponding to the shape of the target artificial marble. For example, a flat plate having a cavity inside a pair of opposed plate members can be used. As a method of casting by a mold, a method of casting into a mold of a desired shape using a metal, a resin, or the like as a material and polymerizing the mold is constituted by two glass plates or metal plates, a soft sealing material, and a clamp. A continuous cell using two stainless steel continuous belts or the like can be used.

  Curing of the resin composition can be performed by heating the mold at a temperature of, for example, 50 to 110 ° C. for 30 to 150 minutes. The heating method at the time of curing molding is not particularly limited, but a known method, for example, a method of heating with a heat source such as hot air, hot water, or an infrared heater can be used.

  Next, a plurality of coating films 4 having different color tones from the base resin 2 and the pattern material 3 and being larger than the pattern material 3 are formed on one surface of the molded body.

  Specifically, the coating film 4 is formed by applying a mixture prepared by mixing a resin, a curing agent, a pigment, an additive, and a solvent with a spray gun or the like.

  A plurality of types of the above-mentioned mixed liquid may be prepared according to a desired color tone of the coating film 4, and the color tone of the coating film 4 may be changed by changing the number of times of application using the same mixed liquid. . Further, by variously changing the combination of a plurality of types of mixed liquids and the number of application times, the coating film 4 having more various color tones can be formed. Further, the color tone of the coating film 4 can be changed by partially overlapping the coating films 4 with each other.

  After the coating film 4 is formed on one surface of the artificial marble 1, for example, a clear coating may be applied to the entire surface to uniformize and protect the coating film surface.

  The artificial marble 1 obtained in this manner is more affected by a difference in light transmittance or refractive index between the base resin 2 and the pattern material 3 and a difference in color tone between the base resin 2, the pattern material 3 and the coating film 4. It has a natural color and a transparent pattern. Further, by forming the coating film 4 on one surface of the artificial marble 1, such a pattern can be stably obtained, and thus the productivity is excellent.

As described above, the embodiments of the present invention have been described in detail. However, specific embodiments are not limited to these embodiments, and even if there is a design change without departing from the gist of the present invention, the present invention is not limited to the embodiments. included.

Claims (5)

A base resin having light transmittance, and a base resin and a pattern formed on a resin composition containing a pattern material having a different light transmittance or refractive index from the base resin, the base resin and the pattern The material is different in color tone and a plurality of irregularly shaped coating films larger than the pattern material are formed,
It said one surface, I face der opposite the artificial marble design surface, artificial marble said coating is characterized in that not exposed to the design surface. One surface of artificial marble formed by molding a base resin having light transmittance and a resin composition containing a plurality of pattern materials having sizes of 5 mm ^{2 to 1} cm ² different in light transmittance or refractive index from the base resin. A plurality of irregularly shaped coating films having different color tones from the base resin and the pattern material and larger than the pattern material are formed,
One size of the coating film is in the range of ^{1cm 2 ~1000cm} 2,
The coating film is formed over at least two of the pattern members ,
The artificial marble, wherein the one surface is a surface opposite to a design surface of the artificial marble, and the coating film is not exposed on the design surface . A base resin having light transmittance, and a base resin and a pattern formed on a resin composition containing a pattern material having a different light transmittance or refractive index from the base resin, the base resin and the pattern A material having a different color tone and an irregularly shaped coating film larger than the pattern material is formed with a plurality of gaps therebetween ,
The artificial marble, wherein the one surface is a surface opposite to a design surface of the artificial marble, and the coating film is not exposed on the design surface .   The artificial marble according to any one of claims 1 to 3, wherein the pattern material has optical transparency.   A light-transmitting base resin, and a light-transmitting or refractive index having a size different from that of the base resin of 5 mm ² ~ 1cm ² After obtaining a molded body by molding a resin composition containing a plurality of pattern materials, the base resin and the pattern material are formed on one surface of the molded body, which is a surface opposite to the design surface of artificial marble. A mixed liquid having a different color tone is applied so as to straddle at least two of the pattern materials, and the base resin and the pattern material have different color tones and a plurality of irregularly shaped coating films larger than the pattern material. A method for producing artificial marble, characterized in that it is formed so as not to be exposed on a design surface.

Images