JPH09227188A - High density artificial stone having nonslip property on mirror surface and its production - Google Patents

Abstract

PROBLEM TO BE SOLVED: To obtain a product closely analogous to a natural stone both in appearance and properties and further having chic feature and deepness which are hardly obtained in a natural stone, and thus enable the use of a high density artificial stone having nonslip property, which is effectively replaceable of a natural stone, around entrances of a building getting wet in rainy days, in an outer groove, at a park, or on a floor of a bath room, etc., easily getting wet. SOLUTION: A mixed composition, in which the weight ratio of an inorganic fine granule component of 5-70 mesh in particle size and an inorganic small granule component of >=70 mesh in particle size is 1:1 to 5:1, the content of the total of the inorganic components is >=85wt.% in a product, and the resin component is contained in an amount of <=15wt.%, is charged into a board- shaped or tubular forming mold and formed. The surface of the formed body is polished, and subsequently the resin component on the surface part is removed by the pressure of water jet.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a mirror surface non-slip high density artificial stone. More specifically, the present invention has excellent designability of granite,
Further, the present invention provides an artificial stone having a non-slip effect, which is useful as a building finishing material and the like.

[0002]

[Prior art and its problems] around the entrance of a building in rainy weather,
On floors that are easily wet with water, such as outer ditches, parks, or bathrooms, it is common knowledge in architectural design not to use a mirror-finished product of natural stone or artificial stone alone to prevent a fall accident. In general, a method of arranging only a roughened natural stone or a mirror-finished product on a part of the natural stone is used.

Therefore, it is conceivable that the surface of the artificial stone, which has been mirror-finished, is subjected to unevenness processing as in the case of natural stone, and this is arranged as a building finishing material in the above-mentioned place. At present, there is no artificial stone that has a good texture and texture and embodies the excellent quality of granite. Conventionally, as a method of giving unevenness to the surface of natural stone, there is a jet burner method that causes interfacial separation due to the difference in thermal expansion of minerals, and a finish that physically destroys the surface by the impact of iron balls or fleas. Was mainly used, and the Tataki finishing method was mainly used in cement-based artificial stone (terazo).

However, in the case of resin-based (acrylic, unsaturated polyester, etc.) artificial stones, the jet burner method cannot be used as a method of giving unevenness to the surface, and when the Tataki finishing method is used, colored aggregates are used. Even if you use
Even if the resin is mixed with a pigment, the split surface becomes white,
There was a drawback that the coloring itself was meaningless.
In addition, there is also a product in which a groove with a width of 2 to 5 mm and a depth of 1 to 5 mm is processed in a mirror-finished product, but this surface is entirely covered with a resin coating, and this is a resin product such as abrasion resistance and designability. Has become equivalent to.

Therefore, in order to give the non-slip processing to the artificial stone, a water polishing finishing method is generally known,
Further, in Japanese Patent Application No. 4-313337, the surface portion of a molded body after molding is treated with an organic solvent, and the resin component is softened or melted to be removed to expose the fine particle component to the surface portion. There is disclosed a method of forming unevenness by using a wire brush, a cutting means, or the like to form unevenness by scraping off a resin component having a low hardness from the surface portion.

However, even in these methods,
It is difficult to make fine irregularities without impairing the color tone of the mirror-finished artificial stone surface. The present invention has been made in view of the circumstances as described above, and gives the texture of natural stone, and is a cheaper stone and recovered fine-grained powder,
To provide a high-quality new artificial stone that has a non-slip effect by subjecting the surface to unevenness using other inorganic raw materials and can be easily used for various purposes, and a manufacturing method thereof. Has an aim.

[0007]

The present invention has been made to solve the above problems, and comprises an inorganic fine particle component of 5 to 70 mesh and an inorganic fine particle component of 70 mesh or more. The weight ratio is 1: 1 to 5: 1, the sum of which is 85% by weight or more of the product, and the resin component is 15%.
There is also provided a mirror-like non-slip high density artificial stone having a mixed composition of not more than wt% and having a fine grain component exposed on the surface.

Further, according to the present invention, the resin component is removed on the surface portion by the pressure of a water jet,
An artificial stone having a non-slip property by exposing fine grain components is a preferred embodiment. Further, the present invention further comprises an inorganic fine particle component having a size of 5 to 70 mesh and 70
The weight ratio of the fine particles of the inorganic particles above the mesh is 1: 1 to 1
5: 1, the sum of which is 85% by weight or more of the product and the resin component is 15% by weight or less, and the mixture is put into a plate-shaped or cylindrical molding die to be molded and surface-polished. later,
Also provided is a method for producing a specular non-slip high density artificial stone, which is characterized in that the resin component of the surface portion is removed by the pressure of a water jet.

[0009]

DETAILED DESCRIPTION OF THE INVENTION The present invention will now be described in more detail. First, the raw materials constituting the artificial stone of the present invention are roughly classified into three components. One is a fine grain component with a size of 5 to 70 mesh, which is a natural stone such as silica stone or granite, an artificial substance such as ceramics or glass, or a glaze containing a coloring pigment on the surface of the crushed substance. Baking with etc. (about 100
Appropriate fine-grained components selected from those (0 ° C.) are used. Some of these small pieces may be mixed in these.

Further, it is used together with this fine grain component.
Although fine particles of 0 mesh or more are also used, various fine particles of natural or artificial can be used as the fine particles. For example, calcium carbonate, aluminum hydroxide, aluminum oxide and the like are fine particle components that are easily obtained. The third component is a resin component. The resin component can be selected in a wide range from thermosetting ones.

For example, acrylic resin, methacrylic resin (MMA), unsaturated polyester resin and the like are exemplified.
Among them, a methacrylic resin having excellent physical properties required for use as a building material, such as weather resistance and strength characteristics, is particularly preferable. Fine-grained components such as natural stone function as a major factor in the appearance and physical properties of the obtained artificial stone. Particularly, by exposing a part, it becomes a main factor of the color and pattern on the appearance in combination with other components.

The fine-grain component is considerably finer than the fine-grain component than the 70-mesh level, and is located so as to penetrate between each grain of the fine-grain component and fill the space between the grains. It contributes to obtain the properties such as hardness and suppleness of the artificial stone. The weight ratio of the fine grain component to the fine grain component is preferably 1: 1 to 5: 1.
In addition, the resin component wraps the fine-grained component such as natural stone, which is a component forming the skeleton, or the fine-grained component, and contributes to binding the whole, giving elasticity or tensile strength to the product. There is a function.

In the present invention, the composition ratio of these components is important. Particularly important is the composition ratio of the resin component and other components. High density means that fine-grained components and fine-grained components contained in the product are present at a high density, and the degree thereof is, for example, 2 g / cm ³ or more, which is contained in a conventional artificial stone. It is beyond the range. That is, the more the composition ratio of the fine-grained component such as natural stone, which is the skeletal component, in the product, the closer it becomes to natural stone, but if it is too much, it will not be solidified and cannot be used as a product. In addition, the physical properties of the resulting product are poor and cannot be used according to normal usage.

Further, in addition to the inconvenience that it does not harden even if a large amount of fine grain components are used, the obtained product becomes dull and less likely to be called stone. Therefore, the proportions of the fine grain component and the fine grain component used are limited. That is, the weight ratio must be 85% or more, preferably 9%.
0% or more. If it exceeds 98%, the product becomes brittle,
You can only get things that are difficult to use. On the other hand, if it is less than 85%, the product is too soft to obtain stone-like properties, and the range of use is the same as that of the resin plate.

This means that components other than fine-grained components such as natural stones and fine-grained components, that is, resin components should not be present in the product at a weight ratio of more than 15% at most. And in this invention, more preferably, 1
It is 0% or less. If the resin component exceeds about 15%, the product becomes plastic, and artificial stone is no longer only apparent. In addition, reducing the resin content may increase the stone tendency of the product, but the product becomes brittle and unsuitable for use. In reality, it has been difficult to reduce the content of conventional resin components to 10% or less.

The fine-grain component has a size of 5 to 70 mesh as described above, but it is preferable to use those having a relatively same size except for special cases. For example, in the case of using a colored material and a non-colored material to add a darker color to the top or bottom, it is possible to change the size of the fine particles depending on the presence or absence of color. Large amount of use, although different, should not be used as it deteriorates the strength of the product.

The size of the fine-grain component particles must be such that they can sufficiently enter between the fine-grain component particles as described above. Therefore, it is not preferable that the particle size of the fine-grain component is close to that of the particle. Further, what is important in the high density artificial stone of the present invention is that, except for special cases, it is desirable that these material compositions are uniformly dispersed in every part of the product.

Further, in obtaining artificial stone, its color tone is one of the important requirements for determining the value of artificial stone.
For example, in natural granite, there are many kinds of colors themselves, from completely black to white or red, and even if the colors are the same, the degree is different. Therefore, in order to give a color corresponding to these, for example, to obtain a black one, it is sufficient to use only a black one of a granular material such as natural stone, but it is difficult to reproducibly obtain an intermediate tone product. It is accompanied. It is not easy to give the distinctive luster of granite even if you give more color.

In the present invention, fine particles obtained by crushing quartz natural stone are used as fine particle components when a glossy one such as granite is to be obtained. The fine particles obtained by crushing quartz-based natural stone have a unique smooth surface on the surface because the raw material is quartz-based. In many cases, it is colorless and transparent.
When it has a color, it is not so strong, and when it is not transparent, it still retains some transparency.

When the raw material selected in this way is used, the color of the product obtained is mainly the color of the resin. Moreover, due to the presence of the fine-grained quartz-based component, the color can be seen as glossy. Even when a pigment or the like is added to the resin component to add color to the product, a product having a uniform color and a unique color tone can be obtained if the fine-grain component is made of quartz.

In the case of giving color to the product, the fine grain component obtained by crushing quartz-based natural stone is used as it is without any processing, and in addition to this, as a color component, it has almost the same size as the fine grain component. It is also possible to give a color to the product by using a mixture of granules having a granular shape and being mixed. At this time, if the mixing ratio of the unprocessed quartz-based fine-grain components and the colored ones is made constant, a product having a constant color tone can be obtained. In this case, the product obtained is much easier in color reproducibility than the conventional resin side is colored or a pigment is used, and there is no discoloration and the gloss is accurately reproduced. It is superior to the conventional coloring methods.

It is also effective to apply a glaze for coloring ceramics or the like to a natural powder and granulate, and bake it to obtain a powder of a desired color and use it as a fine grain component. By using this method, not only can the color of the colored body be assured, but a wide range can be selected. If you use the same crushed quartz-type natural stone as the granular powder and use it as the fine-grained component, and apply a glaze to it and bake it, the color will change to black or red. There is no concern about the reproducibility, and the colors to be reproduced are not only the colors themselves but also the luster and the color tone, so that the conventional coloring method cannot be achieved at all.

In the present invention, the mirror-like non-slip artificial stone in which the fine grain component is exposed on the surface is used. Specifically, in this case, the surface is polished after being formed into a predetermined shape. It is realized by processing it to a mirror surface and then removing only the matrix portion of the resin and the fine particle component with a predetermined area and a predetermined depth of the surface. This removal is
A ratio of about 10 to 60% of the total surface area is preferable, and the depth for removal, that is, the cutting depth of the exposed fine grain component from the polished surface is generally 0. It is preferably about 1 to 1.5 mm.

As a result, even if it is an artificial stone,
The color tone is excellent, and the remarkable effect of mirror-like non-slip property can be obtained. More specifically,
In the present invention, a mixed composition of an inorganic fine particle component and an inorganic fine particle component, a plate-shaped, into a molding die into a predetermined shape such as a tubular shape, and molded, after mirror-finishing by surface polishing, By injecting high-pressure water onto the artificial stone surface with a water jet device, only the inorganic fine particle component, which is the matrix part other than the inorganic fine particle component, is cut, so irregularities are formed on the artificial stone surface, which is excellent for granite. It becomes possible to manufacture a high-density artificial stone having a design property and non-slip property.

Explaining the water jet,
Generally, the water pressure of the water jet is 300 kg /
cm ² or more, about nozzle diameter 0.1 to 1.0 mm, distance from the nozzle tip to the work surface, it is a criterion for the order of 10~100mm according to the cutting depth of the. Less than,
Examples will be described in more detail to describe a mirror-like non-slip high density artificial stone and a method for manufacturing the same.

[0026]

EXAMPLE A silica stone having a grain size of 7.5 to 50 mesh and aluminum hydroxide having an average grain size of 30 μm were used in a weight ratio of 72: 2.
8 to be 87.8% of the total weight of the composition 1
A 2.0% by weight methacrylic resin and a 0.2% by weight peroxide-based curing agent were uniformly mixed to obtain a mortar.

This composition was placed in a mold to a thickness of about 1
It was molded into a 0 mm plate-shaped body. Next, after mirror-polishing the surface, a pressure of 1200 kg / cm ² (nozzle diameter 0.3 mm,
By spraying water with a spray distance of 40 mm), only a mixed portion of the inorganic fine particle component and the resin component in the matrix portion has a depth of 0.
A fine grain component was exposed by cutting with a thickness of 2 to 0.5 mm in a proportion of about 35% with respect to the total surface area of the plate.

The obtained artificial stone had a perfect granite-like design, had no bubbles inside or on the surface, and had a uniform composition. Also, specific gravity 2.45, bending strength 31.1 kg /
cm (according to JIS A5209 ceramic tile test method) and a water absorption rate of 0.1%, which was in a state close to that of natural granite. Fine specular particles were exposed on the surface and had non-slip properties.

[0029]

As described in detail above, the present invention provides a high-density artificial stone containing a high-density natural stone or the like, which has not been obtained in the past, and a method for producing the same. Can give a product that is similar to natural stone in terms of appearance properties, and that is uniform and difficult to obtain in natural products.

Further, according to the present invention, it is possible to manufacture a non-slip artificial stone, which was difficult with a resin artificial stone, and it is easy to get wet with water such as a building entrance, an outer groove, a park, or a bathroom in rainy weather. This non-slip high density artificial stone can be placed on the floor instead of natural stone.

Claims (3)

[Claims] 1. The weight ratio of the fine inorganic particle component having a size of 5 to 70 mesh and the fine inorganic particle component having a size of 70 mesh or more is 1: 1 to 5: 1, and the sum thereof is 85% by weight or more of the product. In addition, the mirror surface non-slip high density artificial stone is characterized in that the resin component has a mixed composition of 15% by weight or less and the fine grain component is exposed on the surface. 2. The mirror surface non-slip high density artificial stone according to claim 1, wherein the resin component is removed by the pressure of the water jet, and the fine grain component is exposed to have a non-slip property. 3. The weight ratio of the fine inorganic particle component having a size of 5 to 70 mesh and the fine inorganic particle component having a size of 70 mesh or more is 1: 1 to 5: 1, and the sum thereof is 85% by weight or more of the product. In addition, the mixed composition containing 15% by weight or less of the resin component is put into a plate-shaped or cylindrical molding die for molding, and after the surface polishing, the resin component on the surface portion is removed by water jet pressure. A method for producing a mirror-like non-slip high-density artificial stone, which is characterized by the above.