JPH0739171B2 - Artificial marble and manufacturing method thereof - Google Patents

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an artificial marble and a method for producing the same.

[0002]

2. Description of the Related Art Conventionally, artificial marble obtained by mixing an unsaturated polyester resin which constitutes an intermediate layer and the like with an inorganic material and hardening the mixture to form an inorganic material has been widely used. This artificial marble has a profound feeling, and can express various tastes and textures by arbitrarily selecting the type of inorganic material to be mixed. Conventionally, unsaturated polyester resin in which mica is scattered (Japanese Patent Application No. 61-25541), stones such as granite (Japanese Unexamined Patent Publication No. 62-197457), and vinylon Those in which fibers are scattered (Japanese Patent Application Laid-Open No. 57-123
No. 859), and various artificial marbles in which scale-like glass flakes are scattered (JP-A-2-153966).

[0003]

Artificial marble exhibiting brilliance contains mica and scaly glass flakes as described above, but the reflected color is dispersed by the reflected light and the transmitted color. The mica has an interference function of coloring like soap bubbles by interference, and the scale-like glass flakes have a function very similar to the interference function, thereby expressing a glittering color tone. However, in the above-mentioned conventional technique, since the light reflection / transmission property of only the mixed inorganic material (mica, glass flake) is used, there is a natural limitation on the light brightness (vividness) and the depth. There is a problem in appearance that the feeling and profound feeling are not satisfied.

The present invention has been made in view of the conventional circumstances, and the object thereof is a novel artificial marble which is brighter and deeper than the conventional artificial marble, has a higher quality, and has a profound feeling. It is to provide the manufacturing method.

[0005]

Means for Solving the Problems The inventors of the present invention have conducted earnest research on an inorganic material to be mixed and an intermediate layer containing the inorganic material. As a result, the inorganic material and the intermediate layer cooperate with each other. The present inventors have found that it is optimal to reflect / transmit light, and have completed the present invention. That is, the present invention is an artificial marble comprising a transparent surface layer, an intermediate layer made of resin concrete, and an FRP back layer, wherein the intermediate layer has no cracks.
A transparent or semi-transparent layer having a color transparent or colored transparent amorphous inorganic material mixed and having fine sealing cracks at the boundary with the amorphous inorganic material, and also as a manufacturing method thereof, A manufacturing method for manufacturing an artificial marble having a three-layer structure of a transparent surface layer, an intermediate layer made of resin concrete, and a back layer made of FRP by a casting method, wherein the transparent surface layer is formed on the surface of the mold. The intermediate layer made of resin concrete is layered and has a desired amount of colorless and transparent resin that has cracks in the unsaturated polyester resin along with a curing agent.
It is prepared by mixing a transparent and colored amorphous inorganic material and a small amount of glass fiber.
A transparent or semi-transparent molding material having a poise of 500 to 1000 poise at 5 degrees is cast into a molding die, and the molding material is heat-cured to a molding exothermic temperature of 60 degrees Celsius or more,
The gist of the invention is that the back layer made of FRP is formed by heating and curing and then is laminated on the molding die in advance or is formed on the molded body after the heat curing. Incidentally, the molding material for the intermediate layer requires a viscosity of 500 to 1000 poise at 25 degrees Celsius. Outside this range, the irregularly shaped granular inorganic material flows in the case of a shaped object such as a bathtub other than a flat plate and cannot be uniformly distributed over the entire intermediate layer. Further, a small amount of glass fiber is required to prevent the above-mentioned irregularly shaped inorganic material from settling and to make the bulk per unit volume uniform. Further, the molding heat generation temperature needs to be 60 degrees Celsius or higher. If the temperature is not more than 60 degrees Celsius, a sealing crack cannot be formed at the boundary between the irregular-shaped granular inorganic material and the unsaturated polyester resin by utilizing the difference in coefficient of thermal expansion between the irregular-shaped inorganic material and the unsaturated polyester resin during cooling.

[0006]

According to the above technical means, the following actions are achieved.
(Claim 1) Diffuse reflection / transmission of light from a colorless transparent or colored transparent amorphous granular inorganic material having fine crack-like cracks mixed in the intermediate layer and a boundary portion between the irregular granular inorganic material With the diffuse reflection / transmission of light from the sealing crack, the light is multiply reflected in random directions as it goes deeper in the intermediate layer,
Expresses glittering brightness and depth. (Claim 2)
The viscosity is 500 to 1000 poise at 25 degrees Celsius,
Colorless and transparent with a small amount of glass fibers and cracks or
The intermediate layer mixed with the colored and transparent amorphous inorganic material is formed on the transparent surface layer in a state where the amorphous inorganic material is settled and does not flow and the bulk density per unit volume is constant. By setting the molding exothermic temperature to 60 degrees Celsius or higher, the unsaturated polyester resin at the time of cooling contracts by a factor of 5 or more than the amorphous granular inorganic material and seals at the boundary with the amorphous granular inorganic material. An intermediate layer that naturally forms cracks is layered on the transparent surface layer.

[0007]

Since the present invention is constructed as described above, it has the following advantages. (Claim 1) Random diffuse reflection / transmission of light from a colorless transparent or colored transparent amorphous granular material having cracks and random light from a sealed crack formed at a boundary between the amorphous inorganic material and irregular granular inorganic material. Reflection / transmission is repeated multiple times as it goes deeper in the middle layer, so the depth and unprecedented glitter are expressed with a color tone, and a gorgeous luxury and profound shining brilliance. It is possible to newly provide an artificial marble exhibiting a sexual appearance. (Claim 2) Not only the artificial marble of the above-mentioned claim 1 but also deformed artificial marble such as a bathtub other than a flat plate causes a decrease in yield such as flow, sedimentation, deviation, and deformation of the irregular- shaped granular inorganic material. It can be manufactured reliably and with high accuracy without inviting.

[0008]

Embodiments of the present invention will now be described with reference to the drawings. In this embodiment, claim 2 and claim 1 are described.

The artificial marble A has a transparent surface layer 1 as shown in FIG. 1, an intermediate layer 2 in which an amorphous granular inorganic material 2a is mixed, and an FR.
The back layer 3 made of P is composed of three layers.

The transparent surface layer 1 is a transparent unsaturated polyester resin to which a predetermined curing agent, accelerator, etc. are added.
0.3 to 0.5 on the molding surface b1 'of the male mold b1 of the molding mold B.
It is applied in a thickness of about mm to form a layer (FIG. 3).

The intermediate layer 2 has a mixture of an amorphous granular inorganic material 2a having cracks 2a 'and a small amount of glass fibers 2b and has fine sealing cracks 2c at the boundary with the amorphous granular inorganic material 2a. 26.8% by weight of a transparent or translucent unsaturated polyester resin, which is translucently molded and has a viscosity of 800 poise, and powdered inorganic agent 2
A material obtained by mixing 9.5% and 0.27% by weight of a curing agent, 42.9% by weight of an irregular-shaped granular inorganic material, and 0.54 of glass fiber.
A molding material containing 3% by weight of the prepared molding material is used as a molding space b3 between the molding surface b2 'of the female mold b2 and the transparent surface layer 1.
It is cast into a mold, heat-cured, and then cooled to form a layer (FIG. 4).

The unsaturated polyester resin is colored and transparent,
There is no problem even if it is colored and semi-transparent, and when it is colored, it synergizes with the coloring of the back layer 3 made of FRP, which will be described later, to express a deeper shade.

[0013] amorphous particulate inorganic 2a particle size 0.5mm及至5 mm, refractive index 1.56, specific gravity 2.59, bulk density 1.
1 to 1.3 colorless and transparent or colored transparent glass particles having fine cracks 2a 'in the shape of a crack, and the fine cracks 2 depending on the light transmission angle from the transparent surface layer 1
At a ', light rays diffused and reflected in various directions and rays transmitted from the entire outer surface are generated, and the diffused reflection and transmission of the rays are further repeated as the depth increases, and the light is transmitted to the deepest FRP back layer 3. Let

[0014] Glass fiber 2b length 1.5 mm, and about the fiber diameter 1.0 .mu.m, moderate bulk density per unit volume of preventing and the irregular-sized particulate inorganic 2a precipitation of the amorphous particulate inorganic material 2a To In this embodiment, as described above,
As a result of mixing 0.54% by weight, the bulk density is about 86%.

The intermediate layer 2 is uniformly poured into the molding space b3, then heated at 40 ° C. or higher for about 30 minutes, cured by heat generation, waits for cooling, and is demolded to be layered. In this example, the mold B was heated at 60 degrees Celsius. In addition, even if the molding material is heated to a desired temperature in advance and heated to 40 ° C. or higher, or the molding die B is heated to 40 ° C. or higher after injecting the molding material at room temperature There is no change.

Since the thermal expansion coefficient of the unsaturated polyester resin cured product A'is 17.40 × 10 -5 and the thermal expansion coefficient of the irregular-shaped granular inorganic material 2a is 0.87 × 10 -5, the heat generation temperature at molding is high. The unsaturated polyester resin largely contracts about 5 times as much as the temperature difference between the normal temperature and room temperature, and the sealing crack 2c is naturally formed at the boundary between the unsaturated polyester resin and the cured product A '(FIG. 2). The temperature difference is optimally 35 ° C. or higher, and if the temperature difference is lower than 35 ° C., the sealing crack 2c may not be surely formed at the boundary with the irregular-shaped inorganic material, which is not preferable.

After cooling, the female mold b2 is removed from the mold, and the back layer 3 made of FRP is applied to the molded body A "(FIG. 5).

The back layer 3 made of FRP is formed by impregnating glass fiber with a resin composition prepared by adding a curing agent, an accelerator, a coloring pigment, etc. to an unsaturated polyester resin. Applying a lining to the back surface of the, wait for natural curing and remove from the male mold b1 to form a layer.
It is optional that the back layer 3 made of a material is previously laminated on the molding surface b2 ″ of the female mold b2 and the intermediate layer 2 to be cast is integrated as a medium.

Next, the function of the molded artificial marble A of this embodiment and the function of the manufacturing method thereof will be described. The light transmitted through the transparent surface layer 1 to the intermediate layer 2 is diffused in various directions depending on the incident light angle by the fine cracks 2a 'formed in the colorless transparent or colored transparent irregular shaped granular inorganic material 2a. While passing through the irregularly shaped granular inorganic material 2a while being reflected, and further diffused and reflected by the sealing crack 2c formed at the boundary between the unsaturated polyester resin and the cured product A ', and reaches the back layer 3, In addition to coloring (color) of the back layer 3, a brilliant appearance in which depth and glitter are coexisted is developed (FIG. 2). Also, artificial marble is like a bathtub,
Even when the object other than the flat plate is a molding object, the viscosity of the unsaturated polyester resin and the addition of a small amount of the glass fiber 2b do not cause the irregular granular inorganic material 2a to flow or settle, and also have a bulk density per unit volume. It has a uniform distribution over the entire area, and when the molding heat temperature (60 degrees or higher) is set, the sealing crack 2c
Is reliably formed at the boundary with the cured product A ′ of the unsaturated polyester resin.

When one or both of the intermediate layer 2 and the irregular-shaped granular inorganic material 2a are colored and transparent, they are skillfully fused with the coloring of the back layer 3 to give a novel hue to the glittering glitter. It can be expressed with depth and taste. Of course, the back layer 3 may be colored white and the intermediate layer 2 and the amorphous granular inorganic material 2a may be used to create a color tone.

Further, the addition amount of the above-mentioned glass fiber 2b,
The mixing amount of the irregular-shaped granular inorganic material 2a is not limited to the numerical value disclosed in the examples, and the setting temperature is free as long as the molding exothermic temperature of the intermediate layer is 60 degrees Celsius or higher.

[Brief description of drawings]

FIG. 1 is a longitudinal sectional view of an embodiment of claim 1.

FIG. 2 is an enlarged cross-sectional view of a main part of FIG.

FIG. 3 is a vertical cross-sectional view showing a state in which a transparent surface layer is formed on a molding die in the embodiment of claim 2;

FIG. 4 is a vertical cross-sectional view showing a state in which an intermediate layer is laminated on a transparent surface layer.

FIG. 5 is a vertical cross-sectional view showing a state in which an FRP back layer is laminated.

[Explanation of symbols]

A: artificial marble 1: transparent surface layer 2: intermediate layer 3: back layer 2a: amorphous particulate inorganic material 2a ': Crack (crack irregular particulate inorganic material) 2b: Glass fiber 2c: sealing cracks B: mold A ”: Molded body

─────────────────────────────────────────────────── ─── Continuation of the front page (51) Int.Cl. ⁶ Identification code Internal reference number FI technical display location B44F 1/04 9/04 // B29L 31:10

Claims (2)

[Claims] 1. An artificial marble comprising a transparent surface layer, an intermediate layer made of resin concrete, and a back layer made of FRP, wherein the intermediate layer is a colorless transparent layer having cracks.
Artificial marble, which is a transparent or translucent layer having a mixed and fine seal cracks colored transparent amorphous particulate inorganic material at the boundary between the amorphous particulate inorganic material. 2. A manufacturing method for manufacturing an artificial marble having a three-layer structure of a transparent surface layer, an intermediate layer made of resin concrete, and a back layer made of FRP by a casting method. desired amount of colorless transparent or non were stratified on the mold surface, an intermediate layer composed of resin concrete having cracks with a curing agent such as an unsaturated polyester resin component
A transparent or semi-transparent molding material prepared by mixing a color-transparent irregular-shaped granular inorganic material and a small amount of glass fiber and having a viscosity of 500 to 1000 poise at 25 degrees Celsius is poured into a molding die. Molded, the molding material is heat-cured to a molding exothermic temperature of 60 degrees Celsius or higher, heat-cured and then cooled, and the FRP back layer is pre-layered on the molding die or molded after the heat-curing. A method for producing artificial marble, which is characterized by being layered on the body.