JPH0339830B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION (Industrial Application Field) The present invention relates to an improvement of a resin concrete (hereinafter abbreviated as resin concrete) molded product having a stone-like pattern and a novel method for manufacturing the same.

(Prior Art) Conventionally, so-called resin molded products using synthetic resin as a concrete binder have been widely used in various fields. Examples of such resin molded products include various terrazzo tiles, construction blocks, and home gardening sinks, which are manufactured by injection molding or hot press molding of a mixture of granular aggregate and thermosetting resin. It will be done. By selecting granular aggregates, so-called polished molded products that look like marble or granite were also developed and began to appear on the market.

(Problems to be Solved by the Invention) However, in the above-mentioned resin molded products, it is difficult to make a so-called marble pattern by mixing various types of granular aggregate at the same time, or to make a uniform pattern by using a single type of aggregate. It is virtually impossible to obtain flowing patterns and other varied patterns like natural stone.
In addition, because gloss and luster are important, bonding resin is often used, and since the entire molded product is made of such resin, it is quite expensive (because the price of bonding resin accounts for a large portion). That was undeniable. Furthermore, due to the characteristics of the molding method, the shapes are limited to relatively simple or shallow shapes, and the lack of variety and price disadvantages of conventional molded products make it difficult to meet the diverse needs of users. was insufficient, and drastic improvements were desired.

(Means for Solving the Problems) The present invention has been made in view of the above, and is a novel stone that has various stone-like patterns like natural stone, can be supplied at low cost, and can also be made into various shapes. The aim is to provide plastic molded products and at the same time propose an effective manufacturing method.

To further explain the present invention in detail based on the accompanying drawings, FIGS. 1A and 2B are partial vertical sectional views of the molded product of the present invention,
The figure is a schematic process diagram of the method of the present invention, and FIGS. 3A, 3B, and 3C are schematic vertical sectional views showing various molds used in the method of the present invention and their molding procedures. That is, the gist of the specific invention of the present invention is that aggregate 11 in the form of lumps or flat granules obtained by crushing natural stones such as kansui stone, limestone, marble, and granite... and a large amount of transparent thermosetting polyester-based A resin concrete surface layer 1 formed by bonding a binder 12 of either resin or acrylic resin and a base layer 2 of resin concrete or FRP containing a large amount of aggregate and filler are laminated together, and the surface layer There is a resin concrete molded product having a stone-like pattern characterized in that the surface of part 1 is a smooth molded surface, and the gist of the second invention is to use natural stones such as kansui stone, limestone, marble, and granite. A step () of mixing aggregate 11 in the form of lumps or flat granules obtained by pulverization with a large amount of transparent thermosetting polyester resin liquid or acrylic resin liquid (monomer) 120; , a step () of spraying the mixture 10 obtained in step () onto the inner surface of the formwork F and curing it to form a surface layer 1 of resin concrete; A resin concrete raw material 20 containing a large amount of aggregate and filler prepared separately is poured into the formwork F [step ()'], or FRP is added to the back side of the surface layer 1.
The raw material 200 is applied and cured to form the surface layer 1.
Step ()'' of forming the base layer part 2 integrated with
A method for manufacturing a resin concrete molded product having a stone-like pattern, comprising the steps of: () demolding the formwork F to obtain a molded product A.

(Function) The present invention will be described in more detail along with its function. For the sake of convenience, the manufacturing method of the second invention will be described first. In step (), the granular aggregate 11... is a particle size of 0.1 to 0.1 obtained by crushing natural stones such as akansuite, limestone, marble, and granite. 3.0 mm lumps or flat granules are most desirable; other examples include chip-shaped granules obtained by crushing hard colored plastics;
Natural gravel or the like surface-coated with a colored synthetic resin, metal foil, or a combination of these with a particle size within the above-mentioned range are also used.
In addition, polyester resin, acrylic resin, or the like is preferably used as the transparent thermosetting resin liquid 120 for bonding the aggregates together. The aggregate 11
... (in the case of the above natural stone) and the resin liquid should be mixed in a ratio of 35 to 90 parts by weight (solid content) per 100 parts by weight of the aggregate, and if the amount of the resin liquid exceeds that range, resin molding will occur. The strength of the product tends to decrease, and on the other hand, when it is less than this range, the sense of depth, which will be described later, tends to decrease. In this process (), in addition to these main materials, fillers with weak coloring power such as calcium carbonate, aluminum hydroxide and mica for the purpose of increasing the volume, hardening accelerators such as cobalt octenoate and cobalt naphthenate, and hardening agents are used. Methyl ethyl ketone peroxide, etc. is added as appropriate, and the mixture is made to have a high viscosity (15 to 30 poise) and a high thixotropy (3 to 6 ).Solvents and adjusting agents are also added to achieve this (however, adjustments can also be made in the resin liquid).

The mixture 10 thus prepared is processed in step ()
In the process, it is sprayed and fixed inside various formworks F...
A spray device S with a nozzle diameter of about 3 mm is used, and the coating is applied to a thickness of 0.5 to 3 mm at a spray pressure of 1 to 5 kg/cm ² . Any of metal molds, plastic molds, wooden molds, silicone rubber molds, etc. can be adopted as the formwork F..., and its shape can also be a flat mold for panels, a three _- dimensional mold (split mold), etc. as shown in Fig. 3. ) F ₂ , undercut type (split type) F ₃ and various other types with complex shapes for exterior use are used. In order to spray the mixture 10 onto the inner surface of this mold F, in the case of a three-dimensional mold _F2 or an undercut mold _F3 , the mixture 10 is sprayed onto the inner surface of each divided mold material before assembly. Then, the formwork F is placed in a baking furnace (not shown) together with the coated mixture 10, and the mixture 10 is hardened to form the granular aggregate 11 and the transparent thermosetting resin binder 1.
2 and 2 are integrally bonded to each other to obtain a surface layer part 1 of a plastic controller.

Next, in step (), a base layer portion 2 is formed on the back surface of the surface layer portion 1, and two methods are used to form this base layer portion 2. That is, the first
The method is to inject the resin material 20 into the formwork F [step ()'], and the second method is to inject the resin material 20 into the formwork F [step ()'].
This is a method of applying the raw material 200 [Step ()'']. In the former case, it is adopted when the formwork F is deep or when it is desired to obtain a heavy panel, while in the latter case, the formwork F is shallow It is used when it is desired to obtain a lightweight panel.In addition, the resin resin raw material 20 is
Unlike the case of forming the surface layer 1, cosmetic properties are not required, so the amount of resin can be reduced and the amount of aggregate or filler can be increased. For example, the mixing ratio is aggregate;
45, filler; 45, resin; 10 (all parts by weight), the resin specifications for normal civil engineering and construction are adopted as they are, and the aggregate can also be gravel for civil engineering, so it can be obtained at a lower cost than the surface layer 1. It will be done. On the other hand, the FRP raw material 200 is also a normal one, and the above surface layer 1
Glass fiber and polyester resin are applied to the back side by simultaneous spraying. Both raw materials injected or applied in this manner are cured to form a base layer portion 2 that is integrally laminated with the surface layer portion 1 .

Then, by removing the mold F, a molded product A is obtained [step ()].

The molded products thus obtained are explained with reference to Fig. 1 A and B. In the molded product A 1 in Fig. ₁ A, the base layer portion 2 is a resin layer, and in the molded product A ₂ in Fig. 1 B, Each indicates that the base layer part 2 is an FRP layer. Surface layer 1
As clarified by the above-mentioned manufacturing method, granular aggregate 11 is a transparent thermosetting resin binder 1 containing a large amount of granular aggregate 11.
2, the aggregates 11
The random arrangement of... and the optical properties of the binder 12 combine to create a deep and unique stone-like pattern. In particular, since a large amount of binder 12 is mixed, a transparent resin layer is reliably formed on the surface, and the deep stone-like pattern is further emphasized. Moreover, this aggregate 11
A variety of patterns can be created by preparing a large number of natural aggregates and artificially colored aggregates, and combining them. Furthermore, since the surface layer 1 is formed by spraying as described above, a plurality of types of mixtures 10 containing different types of aggregates 11 are prepared, and these are separately painted in the same formwork F. By doing so, it is possible to arbitrarily express so-called flowing patterns, block patterns, etc. The surface layer 1 is integrated with the base layer 2, and since the base layer 2 does not affect the appearance, it can be used for ordinary civil engineering and construction that contains a large amount of aggregate and filler as long as the strength does not decrease. Plastics, FRP, etc. are used, and molded product A can be manufactured at low cost. In addition, since conventional resin molded products can only be obtained by injection molding or press molding, only relatively simple shapes can be obtained, but in the molded product A of the present invention, the surface layer 1 is formed by spraying. Since it is formed as a single piece, it is possible to use various types of split formwork F...
Therefore, its uses range from flat panels to complex-shaped exterior products.

(Example) Examples will be described below. The surface layer forming mixture used in each example was prepared with the following formulation.

Material name Mixing ratio (parts by weight) (i) Aggregate; Average particle size 1mm Kansui stone 35 (ii) Transparent thermosetting resin; [Unsaturated polyester resin] 30 (iii) Filler; [Calcium carbonate] 30 (iv) Reinforcing material; [Glass fiber] 2 (v) Additive; [Curing agent, lubricant] 3 Total 100 Example 1 (a) Spread the above mixture on the inner surface of each two-part columnar formwork in a thick layer. It was sprayed to a thickness of 2 mm, and the mold was assembled and hardened in a baking oven.

(b) A resin resin material for the base layer was prepared with the following composition.

Material name Mixing ratio (parts by weight) (i) Aggregate; average particle size 1 mm Kansui stone 55 (ii) Filler; [calcium carbonate] 30 (iii) Resin binder; [unsaturated polyester]
10 (iv) Additives: [Glass fiber, hardener, lubricant]
5 Total 100 (c) The resin raw material was injected and filled into the mold prepared in (a) and cured.

(d) The mold was removed to obtain a columnar molded product in which the resin-rich surface layer of the resin resin and the aggregate (filler)-rich base layer were integrated. The surface of the molded product was smooth, had good luster and luster, and had a deep natural stone-like pattern.

Example 2 (a) The above mixture was applied to the inner surface of a flat mold to a thickness of 2 mm.
It was spray applied and cured.

(b) An FRP raw material for the base layer was prepared, and glass fiber and polyester resin were simultaneously sprayed and cured on the back surface of the surface layer obtained in (a) to form an FRP base layer with a thickness of 20 mm.

(c) The mold was removed to obtain a panel-shaped molded product in which the resin-rich resin surface layer and the FRP base layer were integrated. The surface of the molded product was smooth, had good luster and luster, exhibited a deep natural stone-like pattern, and was lightweight, making it highly suitable as an interior or exterior material for buildings.

In addition to the above-mentioned examples, when the same method was carried out by changing the type and combination of aggregates and also changing the shape of the formwork, it was found that a rich variety of deep stone-like patterns were obtained.・A plastic molded product with extremely high commercial value was obtained, which can be applied to a wide range of fields from exterior materials to exterior products.

(Effects of the Invention) As described above, the resin molded product with the stone-like pattern of the present invention combines the mosaic pattern of the granular aggregate and the optical effect of the transparent resin binder to create a deep pattern with high commercial value. Since the surface layer, which exhibits a pattern and is responsible for the design, and the base layer, which is a reinforcing body, are integrated, it has sufficient strength required for this type of molded product, and is also lightweight and cost-effective. It promises a wide range of uses, from interior and exterior building materials to various exterior products. In addition, in producing such a molded product, since the main surface layer is obtained by spraying the mixture onto the inner surface of the mold, it is possible to create a flow pattern that has never been seen before.
In addition, it is possible to easily mold everything from flat panels to complex shapes, and the above molded products can be made in a wider variety of types.The present invention, which has these numerous advantages, is of great value. I can say that there is.

[Brief explanation of the drawing]

Figures 1A and 1B are partial longitudinal sectional views of the molded product of the present invention;
Figure 2 is a schematic process diagram of the method of the present invention, Figure 3 A,
B and C are schematic longitudinal cross-sectional views showing various molds used in the method of the present invention and their molding procedures. (Explanation of symbols), 1...surface layer part, 10...mixture,
DESCRIPTION OF SYMBOLS 11... Granular aggregate, 12... Transparent thermosetting resin binder, 120... Transparent thermosetting resin liquid, 2... Base layer part, 20... Resin concrete raw material, 200...
FRP raw materials, F...formwork.

Claims (1)

[Scope of Claims] 1. Aggregate in the form of lumps or flat particles obtained by crushing natural stones such as kansui stone, limestone, marble, and granite, and a large amount of transparent thermosetting polyester resin or acrylic resin. A surface layer of resin concrete formed by bonding one of the binders and a base layer of resin concrete or FRP containing a large amount of aggregate and filler are laminated together,
A resin concrete molded product having a stone-like pattern, characterized in that the surface of the surface layer is a smooth molded surface. 2 Aggregate in the form of lumps or flat granules obtained by crushing natural stones such as kansui stone, limestone, marble, and granite, and a large amount of transparent thermosetting polyester resin liquid or acrylic resin liquid. a step of mixing, a step of spraying and fixing the mixture on the inner surface of the formwork and curing it to form a surface layer of resin concrete, and a separately prepared aggregate and filler in the formwork to which the surface layer is fixed. A step of injecting a resin concrete raw material containing a large amount of 1. A method for producing a resin concrete molded product having a stone-like pattern, the method comprising: obtaining a molded product using a stone-like pattern.