WO2004000521A1 - Process for producing artificial marble having both granular pattern and stripe pattern - Google Patents
Process for producing artificial marble having both granular pattern and stripe pattern Download PDFInfo
- Publication number
- WO2004000521A1 WO2004000521A1 PCT/JP2003/007595 JP0307595W WO2004000521A1 WO 2004000521 A1 WO2004000521 A1 WO 2004000521A1 JP 0307595 W JP0307595 W JP 0307595W WO 2004000521 A1 WO2004000521 A1 WO 2004000521A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- curable composition
- resin particles
- artificial marble
- pattern
- comb
- Prior art date
Links
- 239000002928 artificial marble Substances 0.000 title claims abstract description 40
- 238000000034 method Methods 0.000 title abstract description 22
- 239000000203 mixture Substances 0.000 claims abstract description 142
- 239000002245 particle Substances 0.000 claims abstract description 64
- 229920005989 resin Polymers 0.000 claims abstract description 64
- 239000011347 resin Substances 0.000 claims abstract description 64
- 238000000465 moulding Methods 0.000 claims abstract description 24
- 238000004519 manufacturing process Methods 0.000 claims description 24
- 238000000227 grinding Methods 0.000 claims description 6
- 238000010298 pulverizing process Methods 0.000 claims description 2
- 239000011342 resin composition Substances 0.000 claims 1
- 238000005266 casting Methods 0.000 abstract description 2
- 239000003086 colorant Substances 0.000 description 18
- 235000013339 cereals Nutrition 0.000 description 10
- 239000000945 filler Substances 0.000 description 10
- 239000006188 syrup Substances 0.000 description 9
- 235000020357 syrup Nutrition 0.000 description 9
- 239000006185 dispersion Substances 0.000 description 8
- 238000009472 formulation Methods 0.000 description 8
- 239000000463 material Substances 0.000 description 8
- 238000003756 stirring Methods 0.000 description 8
- -1 red Chemical compound 0.000 description 7
- 238000002156 mixing Methods 0.000 description 5
- UQSXHKLRYXJYBZ-UHFFFAOYSA-N Iron oxide Chemical compound [Fe]=O UQSXHKLRYXJYBZ-UHFFFAOYSA-N 0.000 description 4
- 239000003795 chemical substances by application Substances 0.000 description 4
- 239000007788 liquid Substances 0.000 description 4
- 229920000642 polymer Polymers 0.000 description 4
- 239000004372 Polyvinyl alcohol Substances 0.000 description 3
- 239000000654 additive Substances 0.000 description 3
- 238000005520 cutting process Methods 0.000 description 3
- 238000010586 diagram Methods 0.000 description 3
- 239000010438 granite Substances 0.000 description 3
- 239000003112 inhibitor Substances 0.000 description 3
- 239000003999 initiator Substances 0.000 description 3
- 238000010030 laminating Methods 0.000 description 3
- 125000005397 methacrylic acid ester group Chemical group 0.000 description 3
- 239000000178 monomer Substances 0.000 description 3
- 229920002451 polyvinyl alcohol Polymers 0.000 description 3
- 239000002023 wood Substances 0.000 description 3
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 2
- VVQNEPGJFQJSBK-UHFFFAOYSA-N Methyl methacrylate Chemical compound COC(=O)C(C)=C VVQNEPGJFQJSBK-UHFFFAOYSA-N 0.000 description 2
- SMWDFEZZVXVKRB-UHFFFAOYSA-N Quinoline Chemical compound N1=CC=CC2=CC=CC=C21 SMWDFEZZVXVKRB-UHFFFAOYSA-N 0.000 description 2
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 description 2
- 239000005083 Zinc sulfide Substances 0.000 description 2
- 239000006096 absorbing agent Substances 0.000 description 2
- 239000002253 acid Substances 0.000 description 2
- 150000007513 acids Chemical class 0.000 description 2
- 230000000996 additive effect Effects 0.000 description 2
- TZCXTZWJZNENPQ-UHFFFAOYSA-L barium sulfate Chemical compound [Ba+2].[O-]S([O-])(=O)=O TZCXTZWJZNENPQ-UHFFFAOYSA-L 0.000 description 2
- AXCZMVOFGPJBDE-UHFFFAOYSA-L calcium dihydroxide Chemical compound [OH-].[OH-].[Ca+2] AXCZMVOFGPJBDE-UHFFFAOYSA-L 0.000 description 2
- 239000000920 calcium hydroxide Substances 0.000 description 2
- 229910001861 calcium hydroxide Inorganic materials 0.000 description 2
- 239000003054 catalyst Substances 0.000 description 2
- 239000011362 coarse particle Substances 0.000 description 2
- 229910017052 cobalt Inorganic materials 0.000 description 2
- 239000010941 cobalt Substances 0.000 description 2
- GUTLYIVDDKVIGB-UHFFFAOYSA-N cobalt atom Chemical compound [Co] GUTLYIVDDKVIGB-UHFFFAOYSA-N 0.000 description 2
- 239000000975 dye Substances 0.000 description 2
- 239000010408 film Substances 0.000 description 2
- 239000010419 fine particle Substances 0.000 description 2
- 239000003063 flame retardant Substances 0.000 description 2
- 235000013312 flour Nutrition 0.000 description 2
- 238000002347 injection Methods 0.000 description 2
- 239000007924 injection Substances 0.000 description 2
- 239000011256 inorganic filler Substances 0.000 description 2
- 229910003475 inorganic filler Inorganic materials 0.000 description 2
- 238000003475 lamination Methods 0.000 description 2
- VTHJTEIRLNZDEV-UHFFFAOYSA-L magnesium dihydroxide Chemical compound [OH-].[OH-].[Mg+2] VTHJTEIRLNZDEV-UHFFFAOYSA-L 0.000 description 2
- 239000000347 magnesium hydroxide Substances 0.000 description 2
- 229910001862 magnesium hydroxide Inorganic materials 0.000 description 2
- 239000004579 marble Substances 0.000 description 2
- 239000012766 organic filler Substances 0.000 description 2
- 239000000049 pigment Substances 0.000 description 2
- 238000006116 polymerization reaction Methods 0.000 description 2
- 229920001343 polytetrafluoroethylene Polymers 0.000 description 2
- 239000004810 polytetrafluoroethylene Substances 0.000 description 2
- 229910001220 stainless steel Inorganic materials 0.000 description 2
- 239000010935 stainless steel Substances 0.000 description 2
- 239000002562 thickening agent Substances 0.000 description 2
- OGIDPMRJRNCKJF-UHFFFAOYSA-N titanium oxide Inorganic materials [Ti]=O OGIDPMRJRNCKJF-UHFFFAOYSA-N 0.000 description 2
- 229910052984 zinc sulfide Inorganic materials 0.000 description 2
- DRDVZXDWVBGGMH-UHFFFAOYSA-N zinc;sulfide Chemical compound [S-2].[Zn+2] DRDVZXDWVBGGMH-UHFFFAOYSA-N 0.000 description 2
- QEZDYNRKJXCIFE-WAYWQWQTSA-N (z)-3-carbonoperoxoylhept-2-enoic acid Chemical group CCCC\C(=C\C(O)=O)C(=O)OO QEZDYNRKJXCIFE-WAYWQWQTSA-N 0.000 description 1
- WJQOZHYUIDYNHM-UHFFFAOYSA-N 2-tert-Butylphenol Chemical compound CC(C)(C)C1=CC=CC=C1O WJQOZHYUIDYNHM-UHFFFAOYSA-N 0.000 description 1
- 239000004342 Benzoyl peroxide Chemical group 0.000 description 1
- OMPJBNCRMGITSC-UHFFFAOYSA-N Benzoylperoxide Chemical group C=1C=CC=CC=1C(=O)OOC(=O)C1=CC=CC=C1 OMPJBNCRMGITSC-UHFFFAOYSA-N 0.000 description 1
- JOYRKODLDBILNP-UHFFFAOYSA-N Ethyl urethane Chemical compound CCOC(N)=O JOYRKODLDBILNP-UHFFFAOYSA-N 0.000 description 1
- MHAJPDPJQMAIIY-UHFFFAOYSA-N Hydrogen peroxide Chemical compound OO MHAJPDPJQMAIIY-UHFFFAOYSA-N 0.000 description 1
- 229910000831 Steel Inorganic materials 0.000 description 1
- RKFMOTBTFHXWCM-UHFFFAOYSA-M [AlH2]O Chemical compound [AlH2]O RKFMOTBTFHXWCM-UHFFFAOYSA-M 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- WNROFYMDJYEPJX-UHFFFAOYSA-K aluminium hydroxide Chemical compound [OH-].[OH-].[OH-].[Al+3] WNROFYMDJYEPJX-UHFFFAOYSA-K 0.000 description 1
- IRERQBUNZFJFGC-UHFFFAOYSA-L azure blue Chemical compound [Na+].[Na+].[Na+].[Na+].[Na+].[Na+].[Na+].[Na+].[Al+3].[Al+3].[Al+3].[Al+3].[Al+3].[Al+3].[S-]S[S-].[O-][Si]([O-])([O-])[O-].[O-][Si]([O-])([O-])[O-].[O-][Si]([O-])([O-])[O-].[O-][Si]([O-])([O-])[O-].[O-][Si]([O-])([O-])[O-].[O-][Si]([O-])([O-])[O-] IRERQBUNZFJFGC-UHFFFAOYSA-L 0.000 description 1
- 235000019400 benzoyl peroxide Nutrition 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 229910052793 cadmium Inorganic materials 0.000 description 1
- BDOSMKKIYDKNTQ-UHFFFAOYSA-N cadmium atom Chemical compound [Cd] BDOSMKKIYDKNTQ-UHFFFAOYSA-N 0.000 description 1
- 239000006229 carbon black Substances 0.000 description 1
- 238000004040 coloring Methods 0.000 description 1
- 238000013016 damping Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 239000012530 fluid Substances 0.000 description 1
- 239000004519 grease Substances 0.000 description 1
- 239000001023 inorganic pigment Substances 0.000 description 1
- 229910052742 iron Inorganic materials 0.000 description 1
- WTFXARWRTYJXII-UHFFFAOYSA-N iron(2+);iron(3+);oxygen(2-) Chemical compound [O-2].[O-2].[O-2].[O-2].[Fe+2].[Fe+3].[Fe+3] WTFXARWRTYJXII-UHFFFAOYSA-N 0.000 description 1
- SZVJSHCCFOBDDC-UHFFFAOYSA-N iron(II,III) oxide Inorganic materials O=[Fe]O[Fe]O[Fe]=O SZVJSHCCFOBDDC-UHFFFAOYSA-N 0.000 description 1
- JEIPFZHSYJVQDO-UHFFFAOYSA-N iron(III) oxide Inorganic materials O=[Fe]O[Fe]=O JEIPFZHSYJVQDO-UHFFFAOYSA-N 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 239000011368 organic material Substances 0.000 description 1
- 239000012860 organic pigment Substances 0.000 description 1
- IEQIEDJGQAUEQZ-UHFFFAOYSA-N phthalocyanine Chemical compound N1C(N=C2C3=CC=CC=C3C(N=C3C4=CC=CC=C4C(=N4)N3)=N2)=C(C=CC=C2)C2=C1N=C1C2=CC=CC=C2C4=N1 IEQIEDJGQAUEQZ-UHFFFAOYSA-N 0.000 description 1
- 230000000704 physical effect Effects 0.000 description 1
- 238000005498 polishing Methods 0.000 description 1
- 239000002994 raw material Substances 0.000 description 1
- 238000004062 sedimentation Methods 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- 229920003002 synthetic resin Polymers 0.000 description 1
- 239000000057 synthetic resin Substances 0.000 description 1
- 239000010409 thin film Substances 0.000 description 1
- AAAQKTZKLRYKHR-UHFFFAOYSA-N triphenylmethane Chemical compound C1=CC=CC=C1C(C=1C=CC=CC=1)C1=CC=CC=C1 AAAQKTZKLRYKHR-UHFFFAOYSA-N 0.000 description 1
- 235000013799 ultramarine blue Nutrition 0.000 description 1
- 239000012463 white pigment Substances 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B44—DECORATIVE ARTS
- B44F—SPECIAL DESIGNS OR PICTURES
- B44F9/00—Designs imitating natural patterns
- B44F9/04—Designs imitating natural patterns of stone surfaces, e.g. marble
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C41/00—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor
- B29C41/02—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor for making articles of definite length, i.e. discrete articles
- B29C41/22—Making multilayered or multicoloured articles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2033/00—Use of polymers of unsaturated acids or derivatives thereof as moulding material
- B29K2033/04—Polymers of esters
- B29K2033/12—Polymers of methacrylic acid esters, e.g. PMMA, i.e. polymethylmethacrylate
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
- B29K2105/0002—Condition, form or state of moulded material or of the material to be shaped monomers or prepolymers
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
- B29K2995/0018—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds having particular optical properties, e.g. fluorescent or phosphorescent
- B29K2995/002—Coloured
- B29K2995/0021—Multi-coloured
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/702—Imitation articles, e.g. statues, mannequins
Definitions
- the present invention relates to a method for producing artificial marble having both grain patterns and stripe patterns.
- artificial marble has been used as a component of, for example, a counter of a wash basin or a table top.
- This artificial marble is usually produced by curing a curable composition.
- a method of producing artificial marble having a pattern on the surface a method of mixing a different color synthetic resin material when injecting a liquid resin into a molding cell is disclosed in Japanese Patent Publication No. 59-15668, It is described in, for example, Japanese Unexamined Patent Publication No. 1-3117723.
- these methods have a problem in that the appearance of the pattern is lacking in reproducibility.
- artificial marble is often used by cutting the surface, but this cutting may cause the pattern to disappear or change significantly.
- the difference in the curing speed and the difference in the physical properties between the materials is likely to occur. May decrease.
- Japanese Patent Application Laid-Open No. H10-1288771 discloses a method of manufacturing artificial marble by laminating two or more layers of liquid resins of different colors, moving a comb-shaped member in a molding cell, and then curing. Is described. According to this method, a stripe pattern having a sharp appearance can be easily formed, and the pattern can be easily controlled.
- Japanese Patent Application Laid-Open No. H10-3238488 discloses a comb-shaped member in which one or more layers of liquid resin of different colors are laminated on a layer of liquid resin in which a colorant is unevenly dispersed. A method for producing an artificial marble by moving the steel in a molding cell and then hardening is described.
- the present invention has been made in order to easily and satisfactorily produce an artificial marble having an appearance that is more excellent than that of the above-mentioned conventional technology, for example, having a more luxurious granite tone.
- an object of the present invention is to provide a three-dimensional appearance and texture of natural granite, a deep color pattern, a luxurious feeling, an appearance having a combination of grain pattern and stripe pattern, and these patterns can be formed. It is an object of the present invention to provide a method for producing artificial marble, in which the production of artificial marble is easy.
- Another object of the present invention is to provide a method for producing artificial marble that can be formed continuously in the thickness direction and can exhibit a stripe pattern that does not disappear even when the surface is cut.
- the present invention relates to a method for injecting a curable composition (A) containing 0.5 to 30% by mass of resin particles having a diameter of 0.1 to 5.0 mm into a molding cell, and injecting the curable composition.
- the curable composition (A) is obtained by laminating one or more layers of the curable composition (B) of a different color on (A), and laminating a comb-like member while bringing its teeth into contact with the bottom surface of the molding cell.
- (B) is a method for producing an artificial marble having both a grain pattern and a stripe pattern having a step of hardening after moving through the inside.
- FIG. 1 is a schematic view illustrating an example of a step of moving a comb-shaped member in the present invention.
- FIG. 2 is a schematic diagram illustrating an example of a comb-shaped member used in the present effort.
- FIG. 3 is a perspective view showing the pan-shaped container used in the example of the present invention.
- a plurality of curable compositions serving as raw materials for artificial marble are used.
- the curable composition (A), which is injected first and forms the bottom layer, is a significant product base. It has the following color tone.
- This curable yarn composition (A) contains 0.5 to 30% by mass of resin particles having a diameter of 0.1 to 5.0 mm based on the mass of the curable composition (A).
- the composition of the resin particles is not particularly limited, but is preferably substantially the same as the composition of the portion other than the resin particles in the curable composition (A).
- a typical example is a syrup, which is a mixture of a monomer such as methacrylic acid ester and a polymer thereof, and a filler, a coloring agent, a curing initiator, etc., and the mixture is cured.
- the amount of the syrup constituting the resin particles is preferably 20 to 60% by mass based on the mass of the resin particles. Further, the amount of the filler constituting the resin particles is preferably 40 to 80% by mass based on the mass of the resin particles.
- the filler examples include an inorganic filler such as aluminum hydroxide, magnesium hydroxide, and calcium hydroxide, and an organic filler such as wood flour. Further, it is preferable that the particles are colored.
- the coloring agent used for this purpose include, for example, inorganic pigments such as titanium oxide, zinc sulfide, barium sulfate, iron oxide, carbon black, red iron, red, cadmium red, cobalt blue, and cobalt purple; and phthalocyanine and azo-based pigments. And triphenyl methane-based, quinoline-based organic pigments.
- various components conventionally known as additive components of artificial marble for example, dyes, ultraviolet absorbers, flame retardants, release agents, fluidizers, thickeners, polymerization inhibitors, acids It is also possible to add an inhibitor.
- a preferred example of the method for producing the resin particles is a method in which a composition comprising these components is cured and then the hardened material is ground.
- the grinding means include a ball mill, a rod mill, a tower-type grinder, a vibration mill, a mouth mill, a brake crusher, a roll crusher, and a hammer mill. These crushing means may be used in combination.
- the diameter of the resin particles is in the range of 0.1 to 5.0 mm. If the diameter is set to 0.1 mm or more, satisfactory aesthetic properties can be obtained in artificial marble, which is a polymerized and cured composition. However, when the diameter is larger than 5.0 mm, for example, when resin particles having a diameter of about 5.0 mm to 15.0 mm are present, impact resistance, heat crack resistance, etc. tend to be deteriorated. .
- the diameter of the resin particles should be in the range of 0.1 to 3.0 mm. Preferably, there is.
- the particles are classified after fine powdering, and then divided into fine particles and coarse particles.
- fine powdering By blending the particles of each color tone into fine particles and coarse particles, a deeper color tone and appearance can be obtained. Further, by changing the mixing ratio of the two, it becomes easy to adjust the appearance of the artificial marble.
- the content of the resin particles in the curable composition (A) is in the range of 0.5 to 30% by mass based on the mass of the curable composition (A). This amount is 0.5 mass. If the ratio is less than / 0 , the grain pattern is too small, which is not preferable in appearance. Also, when the content exceeds 30% by mass, appearance is not preferable, and characteristics such as impact resistance and heat crack resistance tend to deteriorate. A more preferred content is 3 to 20% by mass.
- the composition of the portion other than the resin particles in the curable composition (A) is not particularly limited.
- a typical example is a syrup, which is a mixture of a monomer such as methacrylic acid ester and its polymer, and a filler, a colorant, a curing initiator, and the like added thereto.
- the amount of the syrup is preferably 30 to 70% by mass based on the mass of the portion other than the resin particles in the curable composition (A).
- the amount of the filler is preferably 30 to 70% by mass based on the mass of the portion other than the resin particles in the curable composition (A).
- Examples of the filler include inorganic fillers such as hydroxyaluminum, magnesium hydroxide, calcium hydroxide, and organic fillers such as wood flour.
- Examples of the colorant include white titanium oxide and zinc sulfide, yellow iron oxide yellow, black iron oxide black, red iron oxide red, blue ultramarine blue and phthalocyan blue.
- Examples of the curing catalyst include tertiary butyl peroxymaleic acid, benzoyl peroxide, tamen hydroperoxide, tertiary butyl phenol dropperoxide, tertiary butyl lauroyl, and azobisisobutyrate.
- additive components of artificial marble for example, dyes, ultraviolet absorbers, flame retardants, release agents, fluidizing agents, thickeners, polymerization inhibitors, acids An anti-diding agent and the like can also be added.
- a preferred example of the curable composition (A) is a hardening composition in which a colorant is dispersed non-uniformly.
- Such heterogeneous dispersion compositions may, for example, be deposited in the composition. It can be produced by adding a coloring agent and stirring insufficiently. The degree of uneven dispersion of the colorant can be changed according to the appearance requirements of each product, but at least the colorant is uniformly dispersed in the curable composition (A) visually. It just needs to be able to recognize that it is not. When such a heterogeneous dispersion composition is used, the quality of the obtained artificial marble is improved, and a more natural appearance can be obtained.
- the injection of the heterogeneous dispersion composition into the molding cell can be carried out by various methods, but the heterogeneous dispersion composition imparts a unidirectional flow direction to the flow pattern of the composition having the superiority of the product. It is preferable that it is performed in the same manner as described above, and coincides with the direction of movement of the comb-like member described later.
- the method for injecting the heterogeneous dispersion composition a method in which the supply container for the heterogeneous dispersion composition is relatively moved in one direction with respect to the molding cell and injects the same.
- composition of the curable composition (B) used in the present invention is not particularly limited.
- a typical example is a syrup which is a mixture of a monomer such as methacrylic acid ester and a polymer thereof, and a filler, a colorant, a curing initiator and the like added thereto.
- the amount of the syrup is preferably from 20 to 60% by mass based on the mass of the curable composition (B).
- the amount of the filler is preferably 40 to 80% by mass based on the mass of the curable composition (B).
- the filler, the colorant, the curing catalyst, and other various components the same as the specific examples described above for the curable composition (A) can be given.
- the curable composition (B) may or may not contain resin particles.
- the diameter of the resin particles is preferably not more than 5.0 mm. If this diameter is greater than 5. O mm, for example 5. ⁇ ⁇ ! When resin particles having a diameter of about 15 mm are present, impact resistance, heat crack resistance, and the like tend to deteriorate.
- the content is preferably 30% by mass or less based on the mass of the curable composition (B). If this amount exceeds 30% by mass, the properties such as impact resistance and heat crack resistance tend to deteriorate. A more preferable content is 20% by mass or less.
- a curable composition (A) containing resin particles is injected into a molding cell to form a lowermost layer.
- a curable composition (B) of a different color is layered.
- the curable composition having a different color referred to in the present invention refers to a curable composition having a different color tone, that is, a curable composition having at least one of different coloring concentrations and hues.
- at least two types of curable compositions having different colors are used. That is, three or more different-color curable compositions (A) and (B) may be laminated in three or more layers.
- the curable compositions (A) and (B) are laminated with a uniform thickness over the entire surface in the cell in order to control the appearance of a power pattern.
- the lamination thickness of the curable compositions (A) and (B) is not particularly limited, but the thickness of each layer is preferably about 2 to 20 mm.
- the thickness of the lower layer of the curable composition (A) is appropriately reduced, when the teeth of the comb-shaped member are moved while being in contact with the bottom surface of the molding cell, the upper layer of the curable composition ( B) is preferred because it is easier to reach the bottom of the cell.
- it is preferable to appropriately increase the thickness of the lower layer of the curable composition (A) because the pattern is less likely to be disturbed and the control is easy, and the limitation on the thickness of the artificial marble is eased.
- the viscosity of the curable composition that has a particularly great influence on the method of the present invention.
- One preferable example of the viscosity is a value in the range of 0.3 to 5.0 Pa ⁇ s.
- the comb-like member is cured while the teeth thereof are brought into contact with the bottom surface of the molding cell.
- the compositions (A) and (B) are moved in a carded fashion.
- the exaggerated expression indicates that the curable composition (A) is present at the mark where the teeth of the comb-like member have passed.
- Displaced depressions are formed, into which the different-color curable composition (B) of the upper layer flows. This allows the comb
- the upper layer of the curable composition (B) of a different color penetrates the traces of the teeth of the comb-shaped member up to the bottom of the cell. Will be formed.
- FIG. 1 is a schematic diagram showing an example of the step of moving the comb-like member in the curable composition as described above.
- a curable composition (A) 2 containing resin particles is formed as a lower layer, and a curable composition (B) 3 of a different color is formed on the lower layer to form a laminate.
- the teeth of the comb-shaped member 1 are immersed in both layers to the bottom surface of the lower layer, and the curable composition (B) 3 of the upper layer having a different color flows into the traces of the teeth so as to flow to the bottom surface. Is moving.
- the curable composition (B) of a different color in the upper layer flows into the trace of passage of the teeth of the comb-like member, and only the curable composition (A) in the lower layer flows there.
- the stripe pattern is not formed if it is inserted. Therefore, it is necessary that a depression can be formed in the trace of the passage of the tooth.
- Various factors such as the viscosity of the curable compositions (A) and (B), the moving speed of the comb-like member, the shape of the comb-like member, and the like are interrelated to the occurrence of the depression. Therefore, the conditions for successfully generating the depression are not determined uniformly, but may be determined as appropriate according to various conditions.
- the moving speed of the teeth of the comb member is important in relation to the viscosity of the curable compositions (A) and (B). If the moving speed of the teeth is too slow, no depression can be formed in the trace of the passage of the teeth, so that the upper layer of the different-color curable yarn (B) cannot reach the bottom of the cell, and a stripe pattern cannot be formed.
- the moving speed of the comb-like member is preferably about 1 to 10 cmZ seconds.
- a comb-shaped member is moved linearly to form a linear stripe pattern, but this can be meandered and moved to form a meandering stripe pattern.
- the comb member can also be moved multiple times. This is a preferred embodiment of the method of the present invention, because the stripe pattern fluctuates and changes in spacing when moved a plurality of times, and an artificial marble with a natural taste is obtained.
- FIG. 2 is a schematic diagram illustrating an example of a comb-shaped member used in the present invention.
- the comb-shaped member 4 shown in FIG. 2 includes a plurality of strip-shaped teeth 4 arranged in a line in parallel at desired intervals, and a portion connecting one end of the plurality of teeth 4.
- the length of the teeth of the comb-like member is sufficiently longer than the total number of layers of the entire curable composition so as not to cause unnecessary disturbance of the upper curable composition (B). Is appropriate.
- the width of the teeth (the length perpendicular to the direction of movement of the teeth) is preferably l to 20 mm. The width of the teeth does not correspond to the width of the stripe to be formed, but does affect it.
- the thickness of the teeth (the length in the direction of movement of the teeth) may be any thickness that maintains the mechanical strength of the teeth, and does not significantly affect the formation of the stripe pattern.
- the cross-sectional shape of the tooth is not very streamlined, and a square shape that generates turbulence in the curable composition in the trace of the passage of the tooth is appropriate.
- the shape of the tip of the tooth preferably has a flat surface so as to be able to adhere to the bottom surface of the molding cell. If there is no need to move many times, the number of teeth may be one, and an appropriate number of teeth may be selected according to a desired stripe pattern.
- the curable compositions (A) and (B) are cured after the comb-shaped member is moved to form a stripe pattern on the bottom surface of the layer of the curable composition (A). Then, the hard marriage product is taken out of the molding cell to obtain an artificial marble.
- the artificial marble has a stripe pattern on the surface in contact with the cell bottom. Since this stripe pattern is formed based on fluid mixing of curable compositions of different colors, it is a stripe pattern of a line having a natural fluctuation different from that drawn by a rule. Furthermore, according to the present invention, due to the combination of the color and pattern of the stripe and the color and size of the resin particles contained in the curable composition (A), An entirely new look can be provided.
- the embodiment based on the batch-type casting method has been mainly described, but the method based on the continuous-type cast molding method is also possible.
- the continuous cast molding method for example, a stainless steel belt moving as a cell and a frame for damping a curable composition made of rubber, resin or the like provided on both sides thereof are used. That is, in the present invention, the comb-shaped member is stationary and fixed, and the comb-shaped member is moved in the curable composition by moving the stainless steel belt side (molding cell side). You may make it move oppositely.
- the surface of the artificial marble thus obtained, it is possible to obtain a granite-like appearance that is more taller and of higher commercial value.
- the depth of the surface grinding varies depending on the size of the resin particles added, it is preferable to perform the grinding at a depth equal to or larger than the radius of the largest particle.
- the artificial marble obtained according to the present invention can be used for various purposes, such as kitchen tops, washstands, shadesabs, tables, wall materials, furniture, and interior accessories in houses.
- the cured product is cut into small pieces with a cutting machine, ground with a hammer mill, and separated by a sieve to obtain white 1-grease particles (P 1) having a diameter of more than 0.5 mm and not more than 1.7 mm,
- white resin particle (P2) having a diameter of 1 mm or more and 0.5 mm or less was obtained.
- White resin particles (P 3) having a diameter of 1.7 mm or more and 3.0 mm or less, and a diameter of 0.1 mm or more and 0.5 mm or less in the same manner as in Production Example 1 except for using each component of Formulation 2 shown in Table 1.
- white 2 resin particles (P4) having a size of not more than mm were obtained.
- Black resin particles (P5) having a diameter of 0.1 mm or more and 0.5 mm or less were obtained in the same manner as in Production Example 1 except that each component of Formulation 3 shown in Table 1 was used.
- the curable composition (A1) prepared as described above was injected into a 30 cm square tray-shaped molding cell in a layered manner so as to have a thickness of 7 mm.
- the curable composition (B1) was first transferred to one pan-shaped container shown in FIG. Then, the curable composition (B1) in this container was injected onto the previously injected curable composition (A1) without breaking the interface, and an upper layer having an injection thickness of 7 mm was laminated and formed. .
- the comb-shaped member 1 having the shape shown in FIG. 2 was immersed in one end of the molding cell, and the teeth were moved at a distance of 50 mm / cm2 toward the other end while contacting the bottom surface of the molding cell.
- This comb-shaped member 1 was made of a polytetrafluoroethylene plate having a thickness of 3 mm. The tooth width is 5mm and the tooth spacing is 25mm. After the movement of the comb-like member, the molding cell was covered, and left for 30 minutes while keeping the temperature, thereby obtaining a sheet-like cured product.
- the stiffening composition (A 2) prepared as described above was injected into a 30 cm square tray-shaped molding cell in the same manner as in Example 1.
- the curable composition (B1) was also laminated on the curable composition (A2) in the same manner as in Example 1, and the comb-like member was moved and cured in the same manner as described above, and was polished with a planar paper. After polishing, artificial marble with both subtle hue, depth, and texture was obtained.
- Example 2 a thin film containing white 1 resin particles (Pl, P2), white 2 resin particles (P3, P4), black resin particles (P5), and brown resin particles (P6)
- a black curable composition (A2) was prepared, and a half of the curable composition (A2) was separated and placed in a 30 cm square tray-shaped mold so as to have a thickness of 7 mm. It was poured in layers.
- Example 2 (A2) was laminated in the same manner as in Example 1, and the comb-like member was moved and cured in the same manner as described in Example 1, and was polished with a sandpaper and polished with sandpaper to have both a grain pattern and a stripe pattern. An artificial marble with subtle shades, depth and texture was obtained.
- a curable composition (A2) was prepared. A half of this curable composition (A2) is taken, and 0.03 g of a colorant composition [black pigment (manufactured by Pencolor, trade name 11B1513) and 9.97 g of syrup are mixed well. While stirring the mixture for 10 seconds with a stirring bar so as not to mix completely, to prepare a curable composition (A3) with incomplete mixing. The appearance of this curable composition (A3) had spots of light black and dark black.
- the curable composition (A3) was injected into a 30 cm square tray-like mold so as to have a thickness of 7 mm and while being moved in one direction in a layered manner with respect to the molding cell.
- a gray curable composition (B2) was obtained in the same manner as in Example 3 using the remaining one-half curable composition (A2).
- This curable composition (B 2) was laminated on the curable composition (A 3) in the same manner as in Example 1, and a comb-like member was similarly formed on the curable composition.
- the combination of the grain size and color and the stripe pattern color pattern has, for example, a three-dimensional effect and texture of natural granite, a deep color pattern, It is possible to easily and satisfactorily produce artificial marble having an excellent appearance such as a granite-like appearance.
- the stripe pattern is formed continuously also in the thickness direction of the artificial marble, the pattern does not disappear even if the surface of the artificial marble is cut. Further, by controlling the shape of the teeth of the comb-shaped member and the moving direction of the teeth, the width of the stripe pattern and the running direction can be adjusted. Furthermore, if the components of the base portion and the stripe handle portion of the artificial marble are almost the same, there is no reduction in the mechanical properties of the artificial marble due to the provision of the handle.
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Abstract
A process for producing an artificial marble having both granular pattern and stripe pattern, comprising the steps of casting a hardenable composition (A) containing 0.5 to 30 wt.% of resin particles of 0.1 to 5.0 mm diameter (2) into a molding cell; superimposing in layered form at least one layer of a hardenable composition (B) of different color (3) on the cast hardenable composition (A) (2); moving a pectinate member (1) in the laminated hardenable composition (A) (2) and hardenable composition (B) (3) while keeping contact of the teeth of the pectinate member (1) with the bottom surface of the molding cell; and hardening the compositions.
Description
明 細書 Specification
粒柄とストライプ柄の両方を有する人工大理石の製造方法 Method for producing artificial marble having both grain pattern and stripe pattern
技術分野 Technical field
本発明は、 粒柄とストライプ柄の両方を有する人工大理石を製造する為の方法 に関する。 背景技術 The present invention relates to a method for producing artificial marble having both grain patterns and stripe patterns. Background art
従来より、 人工大理石は、 例えば洗面台のカウンター、 テーブルトップ等の部 材として用いられている。 この人工大理石は、 通常、 硬化性組成物を硬化させる ことにより製造される。 そして、 表面に模様を有する人工大理石を製造する方法 として、 液状樹脂を成形セルへ注入する際に異色の合成樹脂素材を混入させる方 法が、 特公昭 5 9— 1 5 6 8号公報、 特開平 1— 3 1 7 7 2 3号公報等に記載さ れている。 し力 し、 これらの方法は、 模様の現出の再現性に欠けるという問題が ある。 また、 人工大理石は表面を切削加工して用いることが多いが、 この切削に より模様が消失したり、 大幅に変化してしまう場合がある。 更に、 模様の現出の 為に異質の材料を使用する場合は、 硬化速度に差が生じたり材料間で物性差が発 現し易いので、 模様の無いものと比較すると人工大理石としての機械的性能が低 下する場合がある。 Conventionally, artificial marble has been used as a component of, for example, a counter of a wash basin or a table top. This artificial marble is usually produced by curing a curable composition. As a method of producing artificial marble having a pattern on the surface, a method of mixing a different color synthetic resin material when injecting a liquid resin into a molding cell is disclosed in Japanese Patent Publication No. 59-15668, It is described in, for example, Japanese Unexamined Patent Publication No. 1-3117723. However, these methods have a problem in that the appearance of the pattern is lacking in reproducibility. In addition, artificial marble is often used by cutting the surface, but this cutting may cause the pattern to disappear or change significantly. Furthermore, when a different material is used for the appearance of the pattern, the difference in the curing speed and the difference in the physical properties between the materials is likely to occur. May decrease.
特開平 1 0— 1 2 8 7 7 1号公報には、 異色の液状樹脂を二層以上積層し、 櫛 状の部材を成形セル中で移動させた後、 硬化させて人工大理石を製造する方法が 記載されている。 この方法によれば、 鮮明な外観のストライプ柄を簡略に形成で き、 かつ柄のコントロールも容易に行うことができる。 また、 特開平 1 0— 3 2 3 8 4 8号公報には、 着色剤が不均一に分散された液状樹脂の層の上に異色の液 状榭脂を一層以上積層し、 櫛状の部材を成形セル中で移動させた後、 硬化させて 人工大理石を製造する方法が記載されている。 この方法によれば、 微妙な色合い を持ち、 質感、 深み感に富んだ天然木や天然大理石の外観のストライプ柄を形成 でき、 かつ柄のコントロールも容易に行うことができる。 また、 これら方法によ
り製造した人工大理石は、 天然の木質様材料やその他の天然大理石に比べると、 外観の点で優れている。 発明の開示 Japanese Patent Application Laid-Open No. H10-1288771 discloses a method of manufacturing artificial marble by laminating two or more layers of liquid resins of different colors, moving a comb-shaped member in a molding cell, and then curing. Is described. According to this method, a stripe pattern having a sharp appearance can be easily formed, and the pattern can be easily controlled. Japanese Patent Application Laid-Open No. H10-3238488 discloses a comb-shaped member in which one or more layers of liquid resin of different colors are laminated on a layer of liquid resin in which a colorant is unevenly dispersed. A method for producing an artificial marble by moving the steel in a molding cell and then hardening is described. According to this method, it is possible to form a striped pattern having the appearance of natural wood or natural marble, which has a subtle hue and is rich in texture and depth, and the pattern can be easily controlled. In addition, these methods Man-made marble is superior in appearance to natural wood-like materials and other natural marbles. Disclosure of the invention
本発明は、 上述した従来技術よりも、 例えばより高級感のある御影石調を有す るなど、 外観の点で更に優れた人工大理石を簡易かつ良好に製造する為になされ たものである。 The present invention has been made in order to easily and satisfactorily produce an artificial marble having an appearance that is more excellent than that of the above-mentioned conventional technology, for example, having a more luxurious granite tone.
すなわち、 本発明の目的は、 天然の御影石が持つ立体感と質感、 深みのある色 柄を有し、 高級感があり、 粒柄とストライプ柄を併せ持った外観が形成でき、 か つこれらの柄のコントロールが容易である人工大理石の製造方法を提供すること にある。 That is, an object of the present invention is to provide a three-dimensional appearance and texture of natural granite, a deep color pattern, a luxurious feeling, an appearance having a combination of grain pattern and stripe pattern, and these patterns can be formed. It is an object of the present invention to provide a method for producing artificial marble, in which the production of artificial marble is easy.
本発明の他の目的は、 厚み方向にも連続的に形成でき、 表面を切削しても消失 しないストライプ柄を発現させることができる人工大理石の製造方法を提供する ことにある。 Another object of the present invention is to provide a method for producing artificial marble that can be formed continuously in the thickness direction and can exhibit a stripe pattern that does not disappear even when the surface is cut.
そして、 本発明は、 直径 0 . 1〜5 . O mmの樹脂粒子 0 . 5〜3 0質量%を含 む硬化性組成物 (A) を成形セル内に注入し、 注入した硬化性組成物 (A) の上 に異色の硬化性組成物 (B ) を一層以上層状に積層し、 櫛状の部材を、 その歯を 前記成形セルの底面に接触させつつ積層された硬化性組成物 (A) および (B ) 中を移動させた後、 硬化させる工程を有する粒柄とストライプ柄の両方を有する 人工大理石の製造方法である。 図面の簡単な説明 The present invention relates to a method for injecting a curable composition (A) containing 0.5 to 30% by mass of resin particles having a diameter of 0.1 to 5.0 mm into a molding cell, and injecting the curable composition. The curable composition (A) is obtained by laminating one or more layers of the curable composition (B) of a different color on (A), and laminating a comb-like member while bringing its teeth into contact with the bottom surface of the molding cell. ) And (B) is a method for producing an artificial marble having both a grain pattern and a stripe pattern having a step of hardening after moving through the inside. BRIEF DESCRIPTION OF THE FIGURES
図 1は、 本発明において櫛状部材を移動させる工程の一例を示す模式図である。 図 2は、 本努明に用いる櫛状部材の一例を示す模式図である。 FIG. 1 is a schematic view illustrating an example of a step of moving a comb-shaped member in the present invention. FIG. 2 is a schematic diagram illustrating an example of a comb-shaped member used in the present effort.
図 3は、 本発明の実施例で用いたパーン状容器を示す斜視図である。 発明を実施するための最良の形態 FIG. 3 is a perspective view showing the pan-shaped container used in the example of the present invention. BEST MODE FOR CARRYING OUT THE INVENTION
本発明の方法では、 人工大理石の原料となる硬化性組成物を複数種使用する。 最初に注入して最下層を構成する硬化性組成物 (A) は、 製品の有意面でベース
の色調を呈するものである。 この硬化性糸且成物 (A) は、 直径 0 . 1〜5 . 0 mm の樹脂粒子を、 硬化性組成物 (A) の質量を基準として 0 . 5〜3 0質量%含ん でいる。 In the method of the present invention, a plurality of curable compositions serving as raw materials for artificial marble are used. The curable composition (A), which is injected first and forms the bottom layer, is a significant product base. It has the following color tone. This curable yarn composition (A) contains 0.5 to 30% by mass of resin particles having a diameter of 0.1 to 5.0 mm based on the mass of the curable composition (A).
樹脂粒子の組成は特に制限されないが、 硬化性組成物 (A) 中の樹脂粒子以外 の部分の組成とほぼ同等であることが好ましい。 代表的なものとしては、 メタク リル酸エステル等の単量体とその重合体の混合物であるシラップに、 充填剤、 着 色剤、 硬化開始剤等を添カ卩して硬化させたものが挙げられる。 樹脂粒子を構成す るシラップの量は、 樹脂粒子の質量を基準として 2 0〜6 0質量%が好ましい。 また、 榭脂粒子を構成する充填剤の量は、 樹脂粒子の質量を基準として 4 0〜8 0質量%が好ましい。 The composition of the resin particles is not particularly limited, but is preferably substantially the same as the composition of the portion other than the resin particles in the curable composition (A). A typical example is a syrup, which is a mixture of a monomer such as methacrylic acid ester and a polymer thereof, and a filler, a coloring agent, a curing initiator, etc., and the mixture is cured. Can be The amount of the syrup constituting the resin particles is preferably 20 to 60% by mass based on the mass of the resin particles. Further, the amount of the filler constituting the resin particles is preferably 40 to 80% by mass based on the mass of the resin particles.
充填剤としては、 例えば、 水酸化アルミニウム、 水酸化マグネシウム、 水酸化 カルシウム等の無機充填剤や、 木粉等の有機質充填剤が挙げられる。 また、 樹月旨 粒子は着色してあることが好ましい。 その為に用いる着色剤としては、 例えば、 酸化チタン、 硫化亜鉛、 硫酸バリウム、 酸化鉄、 カーボンブラック、 ベンガラ、 朱、 カドミウム赤、 コバルト青、 コバルト紫等の無機顔料や、 フタロシアニン系、 ァゾ系、 トリフエニルメタン系、 キノリン系等の有機顔料が挙げられる。 これら 以外にも、 従来より人工大理石の添加成分として知られている各種の成分、 例え ば染料、 紫外線吸収剤、 難燃剤、 離型剤、'流動化剤、 増粘剤、 重合禁止剤、 酸ィ匕 防止剤等を添加することもできる。 Examples of the filler include an inorganic filler such as aluminum hydroxide, magnesium hydroxide, and calcium hydroxide, and an organic filler such as wood flour. Further, it is preferable that the particles are colored. Examples of the coloring agent used for this purpose include, for example, inorganic pigments such as titanium oxide, zinc sulfide, barium sulfate, iron oxide, carbon black, red iron, red, cadmium red, cobalt blue, and cobalt purple; and phthalocyanine and azo-based pigments. And triphenyl methane-based, quinoline-based organic pigments. In addition to these, various components conventionally known as additive components of artificial marble, for example, dyes, ultraviolet absorbers, flame retardants, release agents, fluidizers, thickeners, polymerization inhibitors, acids It is also possible to add an inhibitor.
樹脂粒子の製法の好ましい例としては、 これら諸成分から成る組成物を硬化さ せた後、 その硬ィヒ物を粉碎する方法が挙げられる。 粉碎手段としては、 例えば、 ボールミル、 ロッドミル、 塔式摩碎機、 振動ミル、 口ールミル、 ブレーキクラッ シヤー、 ロールクラッシャー、 ハンマーミル等がある。 これら粉碎手段は、 組み 合わせて使用してもよい。 A preferred example of the method for producing the resin particles is a method in which a composition comprising these components is cured and then the hardened material is ground. Examples of the grinding means include a ball mill, a rod mill, a tower-type grinder, a vibration mill, a mouth mill, a brake crusher, a roll crusher, and a hammer mill. These crushing means may be used in combination.
樹脂粒子の直径は、 0 . 1〜5 . O mmの範囲内である。 この直径を 0 . 1 mm 以上にすれば、 重合硬化組成物である人工大理石において満足できる美的特性が 得られる。 ただし、 この直径が 5 . 0 mmよりも大きい場合、 例えば 5 . 0 mm〜 1 5 . 0 mm程度の直径の樹脂粒子が存在すると、 耐衝撃性、 耐熱クラック性な どが悪くなる傾向がある。 樹脂粒子の直径は、 特に 0 . 1〜 3 . 0 mmの範囲内で
あることが好ましい。 The diameter of the resin particles is in the range of 0.1 to 5.0 mm. If the diameter is set to 0.1 mm or more, satisfactory aesthetic properties can be obtained in artificial marble, which is a polymerized and cured composition. However, when the diameter is larger than 5.0 mm, for example, when resin particles having a diameter of about 5.0 mm to 15.0 mm are present, impact resistance, heat crack resistance, etc. tend to be deteriorated. . The diameter of the resin particles should be in the range of 0.1 to 3.0 mm. Preferably, there is.
また、 硬化した組成物を粉砕することにより樹脂粒子を製造する場合は、 粉禅 後に分級させて、 細かい粒子と粗い粒子に分けて配合することも好ましい。 各々 の色調の粒子を細かい粒子と粗い粒子に分けて配合することにより、 より深みの ある色調および外観を得ることができる。 さらに両者の混合比を変化させること により、 人工大理石の外観を調整することも容易となる。 In the case where resin particles are produced by pulverizing the cured composition, it is also preferable that the particles are classified after fine powdering, and then divided into fine particles and coarse particles. By blending the particles of each color tone into fine particles and coarse particles, a deeper color tone and appearance can be obtained. Further, by changing the mixing ratio of the two, it becomes easy to adjust the appearance of the artificial marble.
硬化性組成物 (A) 中の樹脂粒子の含有量は、 硬化性組成物 (A) の質量を基 準として 0 . 5〜3 0質量%の範囲内である。 この量が 0 . 5質量。 /0未満では、 粒 の柄が少な過ぎて外観上好ましくない。 また、 3 0質量%を超えた場合も外観上 好ましくなく、 かつ耐衝擊性、 耐熱クラック性等の特性が悪くなる傾向にある。 さらに好ましい含有量は、 3〜2 0質量%である。 The content of the resin particles in the curable composition (A) is in the range of 0.5 to 30% by mass based on the mass of the curable composition (A). This amount is 0.5 mass. If the ratio is less than / 0 , the grain pattern is too small, which is not preferable in appearance. Also, when the content exceeds 30% by mass, appearance is not preferable, and characteristics such as impact resistance and heat crack resistance tend to deteriorate. A more preferred content is 3 to 20% by mass.
硬化性組成物 (A) 中の樹脂粒子以外の部分の組成は、 特に制限されない。 代 表的なものとしては、 メタクリル酸エステル等の単量体とその重合体の混合物で あるシラップに、 充填剤、 着色剤、 硬化開始剤等を添加したものが挙げられる。 シラップの量は、 硬化性組成物 (A) 中の樹脂粒子以外の部分の質量を基準とし て 3 0〜7 0質量%が好ましい。 また、 充填剤の量は、 硬化性組成物 (A) 中の 樹脂粒子以外の部分の質量を基準として 3 0〜7 0質量%が好ましい。 The composition of the portion other than the resin particles in the curable composition (A) is not particularly limited. A typical example is a syrup, which is a mixture of a monomer such as methacrylic acid ester and its polymer, and a filler, a colorant, a curing initiator, and the like added thereto. The amount of the syrup is preferably 30 to 70% by mass based on the mass of the portion other than the resin particles in the curable composition (A). Further, the amount of the filler is preferably 30 to 70% by mass based on the mass of the portion other than the resin particles in the curable composition (A).
充填剤としては、 例えば、 水酸ィヒアルミ-ゥム、 水酸化マグネシウム、 水酸ィ匕 カルシウム等の無機充填剤や、 木粉等の有機質充填剤が挙げられる。 着色剤とし ては、 例えば、 白色の酸化チタンや硫化亜鉛、 黄色の酸化鉄イェロー、 黒色の酸 化鉄ブラック、 赤色の酸化鉄レッド、 青色のウルトラマリンブルーやフタロシア ェンブルー等が挙げられる。 硬化触媒としては、 例えば、 ターシャリープチル パーォキシマレイン酸、 過酸化べンゾィル、 タメンヒドロパーオキサイド、 ター シャリープチノレヒ ドロペルォキサイド、 過酸ィ匕ラウロイル、 ァゾビスイソプチ口 ュトリル等が挙げられる。 これら以外にも、 従来より人工大理石の添加成分とし て知られている各種の成分、 例えば染料、 紫外線吸収剤、 難燃剤、 離型剤、 流動 ィ匕剤、 増粘剤、 重合禁止剤、 酸ィ匕防止剤等を添加することもできる。 Examples of the filler include inorganic fillers such as hydroxyaluminum, magnesium hydroxide, calcium hydroxide, and organic fillers such as wood flour. Examples of the colorant include white titanium oxide and zinc sulfide, yellow iron oxide yellow, black iron oxide black, red iron oxide red, blue ultramarine blue and phthalocyan blue. Examples of the curing catalyst include tertiary butyl peroxymaleic acid, benzoyl peroxide, tamen hydroperoxide, tertiary butyl phenol dropperoxide, tertiary butyl lauroyl, and azobisisobutyrate. Can be In addition to these, various components conventionally known as additive components of artificial marble, for example, dyes, ultraviolet absorbers, flame retardants, release agents, fluidizing agents, thickeners, polymerization inhibitors, acids An anti-diding agent and the like can also be added.
硬化性組成物 (A) の好ましい一例として、 着色剤が不均一に分散された硬ィ匕 性組成物が挙げられる。 このような不均一分散組成物は、 例えば、 組成物中に着
色剤を添加し、 不十分に撹拌すること等により製造できる。 着色剤の不均一な分 散の度合は、 個々の製品に対しての外観要求により変更が可能であるが、 少なく とも目視により硬化性組成物 (A) 中に着色剤が均一には分散されていないこと が認識できればよい。 このような不均一分散組成物を使用すると、 得られる人工 大理石の品位が向上し、 より自然な外観のものが得られる。 成形セル内への不均 一分散組成物の注入は種々の方法で実施できるが、 この不均一分散組成物が製品 の優位面で有する組成物の流れ模様に一定方向の流れの向きを付与するようにし て行い、 後述する櫛状部材の移動の方向と一致しているのが好ましい。 不均一分 散組成物の注入方法は、 不均一分散組成物の供給容器を成形セルに対して一方向 へ相対的に移動させつつ注入する方法などが好ましい例として挙げられる。 A preferred example of the curable composition (A) is a hardening composition in which a colorant is dispersed non-uniformly. Such heterogeneous dispersion compositions may, for example, be deposited in the composition. It can be produced by adding a coloring agent and stirring insufficiently. The degree of uneven dispersion of the colorant can be changed according to the appearance requirements of each product, but at least the colorant is uniformly dispersed in the curable composition (A) visually. It just needs to be able to recognize that it is not. When such a heterogeneous dispersion composition is used, the quality of the obtained artificial marble is improved, and a more natural appearance can be obtained. The injection of the heterogeneous dispersion composition into the molding cell can be carried out by various methods, but the heterogeneous dispersion composition imparts a unidirectional flow direction to the flow pattern of the composition having the superiority of the product. It is preferable that it is performed in the same manner as described above, and coincides with the direction of movement of the comb-like member described later. As a preferable example of the method for injecting the heterogeneous dispersion composition, a method in which the supply container for the heterogeneous dispersion composition is relatively moved in one direction with respect to the molding cell and injects the same.
本発明に用いる硬化性組成物 (B ) の組成は特に制限されない。 代表的なもの としては、 メタクリル酸エステル等の単量体とその重合体の混合物であるシラッ プに、 充填剤、 着色剤、 硬化開始剤等を添カ卩したものが挙げられる。 シラップの 量は、 硬化性組成物 (B ) の質量を基準として 2 0〜 6 0質量%が好ましい。 ま た、 充填剤の量は、 硬化性組成物 (B ) の質量を基準として 4 0〜 8 0質量%が 好ましい。 充填剤、 着色剤、 硬化触媒、 およびその他の各種成分の具体例として は、 硬化性組成物 (A) に関して先に挙げた各種具体例と同様のものを挙げるこ とができる。 The composition of the curable composition (B) used in the present invention is not particularly limited. A typical example is a syrup which is a mixture of a monomer such as methacrylic acid ester and a polymer thereof, and a filler, a colorant, a curing initiator and the like added thereto. The amount of the syrup is preferably from 20 to 60% by mass based on the mass of the curable composition (B). Further, the amount of the filler is preferably 40 to 80% by mass based on the mass of the curable composition (B). As specific examples of the filler, the colorant, the curing catalyst, and other various components, the same as the specific examples described above for the curable composition (A) can be given.
硬化性組成物 (B ) は、 樹脂粒子を含有していてもよいし、 含有していなくて もよい。 樹脂粒子を含有する場合は、 樹脂粒子の直径は 5 . O mm以下であるこ とが好ましい。 この直径が 5 . O mmよりも大きい場合、 例えば 5 . Ο πιπ!〜 1 5 . O mm程度の直径の樹脂粒子が存在すると、 耐衝撃性、 耐熱クラック性などが悪 くなる傾向にある。 The curable composition (B) may or may not contain resin particles. When resin particles are contained, the diameter of the resin particles is preferably not more than 5.0 mm. If this diameter is greater than 5. O mm, for example 5. Ο πιπ! When resin particles having a diameter of about 15 mm are present, impact resistance, heat crack resistance, and the like tend to deteriorate.
また、 硬化性組成物 (B ) が樹脂粒子を含有する場合、 その含有量は、 硬化性 組成物 (B ) の質量を基準として 3 0質量%以下であることが好ましい。 この量 が 3 0質量%を超えると、 耐衝撃性、 耐熱クラック性等の特性が悪くなる傾向に ある。 さらに好ましい含有量は、 2 0質量%以下でぁる。 When the curable composition (B) contains resin particles, the content is preferably 30% by mass or less based on the mass of the curable composition (B). If this amount exceeds 30% by mass, the properties such as impact resistance and heat crack resistance tend to deteriorate. A more preferable content is 20% by mass or less.
本発明においては、 例えば、 まず、 樹脂粒子を含有する硬化性組成物 (A) を 成形セル内に注入し、 最下層を形成する。 次いで、 この注入した硬化性組成物
(A) の上に、 これとは異なる色の硬化性組成物 (B ) を層状に積層させる。 こ の積層の際には、 下層の硬化性組成物 (A) との界面があまり乱れないようにし て、 上層の硬化性組成物 (B ) を注入することが好ましい。 本発明にいう異色の 硬化性組成物とは、 色調の異なるもの、 すなわち着色濃度おょぴ色相の少なくと も一方が異なる硬化性組成物をいう。 また、 本発明の方法では、 硬化性組成物と して異色のものを少なくとも二種用いる。 すなわち、 三種以上の異色の硬化性組 成物 (A) および (B ) を三層以上に積層してもよい。 In the present invention, for example, first, a curable composition (A) containing resin particles is injected into a molding cell to form a lowermost layer. Then, the injected curable composition On top of (A), a curable composition (B) of a different color is layered. In this lamination, it is preferable to inject the upper layer curable composition (B) so that the interface with the lower layer curable composition (A) is not so disturbed. The curable composition having a different color referred to in the present invention refers to a curable composition having a different color tone, that is, a curable composition having at least one of different coloring concentrations and hues. In the method of the present invention, at least two types of curable compositions having different colors are used. That is, three or more different-color curable compositions (A) and (B) may be laminated in three or more layers.
硬化性組成物 (A) および (B ) は、 セル内の全面で均一な厚みで積層されて いること力 模様の発現をコントロールする上で好ましい。 ただし、 部分的に積 層厚にむらが有っても、 これが直接的にストライプ柄と粒柄の発現に影響を与え るものではない。 硬化性組成物 (A) および (B ) の積層厚は特に制限されない 、 各層の厚みは 2〜2 0 mm程度が好ましい。 特に、 下層の硬化性組成物 (A) の層の厚みを適度に薄くすれば、 櫛状の部材の歯を成形セルの底面に接触 させつつ移動させた際に、 上層の硬化性組成物 (B ) がセルの底面に到達するの が容易になるので好ましい。 また、 下層の硬化性組成物 (A) の層の厚みを適度 に厚くすることは、 模様が乱れ難いので制御が容易になると共に、 人工大理石の 切削の厚みの制限も緩和されるので好ましい。 It is preferable that the curable compositions (A) and (B) are laminated with a uniform thickness over the entire surface in the cell in order to control the appearance of a power pattern. However, even if the layer thickness is partially uneven, this does not directly affect the appearance of stripe patterns and grain patterns. The lamination thickness of the curable compositions (A) and (B) is not particularly limited, but the thickness of each layer is preferably about 2 to 20 mm. In particular, if the thickness of the lower layer of the curable composition (A) is appropriately reduced, when the teeth of the comb-shaped member are moved while being in contact with the bottom surface of the molding cell, the upper layer of the curable composition ( B) is preferred because it is easier to reach the bottom of the cell. Also, it is preferable to appropriately increase the thickness of the lower layer of the curable composition (A) because the pattern is less likely to be disturbed and the control is easy, and the limitation on the thickness of the artificial marble is eased.
硬化性組成物 (A) および (B ) に関して、 本発明の方法に対して特に大きな 影響をもつのは、 硬化性組成物の粘度である。 その粘度としては、 0 . 3〜5 . 0 P a · sの範囲内の値であることが、 一つの好ましい例として挙げられる。 粘度 を適切な値にすれば、 樹脂粒子の均一分散ゃストライプ模様の発現をコントロー ルすることが容易になり、 また、 樹脂粒子、 充填剤、 着色剤等の添加物の沈降を 防ぐこともできる。 With regard to the curable compositions (A) and (B), it is the viscosity of the curable composition that has a particularly great influence on the method of the present invention. One preferable example of the viscosity is a value in the range of 0.3 to 5.0 Pa · s. By setting the viscosity at an appropriate value, it becomes easy to control the uniform dispersion of the resin particles and the appearance of the stripe pattern, and it is also possible to prevent sedimentation of additives such as resin particles, fillers, and coloring agents. .
本発明においては、 硬化性組成物 (A) の上に硬化性組成物 (B ) を一層以上 層状に積層した後、 櫛状の部材を、 その歯を成形セルの底面に接触させつつ硬化 性組成物 (A) および (B ) を梳くようにして移動させる。 このように櫛状部材 を硬化性組成物 (A) および (B ) 中で移動させると、 誇張した表現をすれば、 櫛状部材の歯が通過した跡には硬化性組成物 (A) が押しのけられた窪みが生じ、 そこへ上層の異色の硬化性組成物 (B ) が流れ込むことになる。 これにより、 櫛
状部材の歯の通過跡にはセルの底面まで上層の異色の硬化性組成物 (B ) が侵入 して、 底面を有意面とした場合に、 櫛状部材の歯の通過跡にストライプ柄が形成 されることになる。 In the present invention, after the curable composition (B) is layered on the curable composition (A) in one or more layers, the comb-like member is cured while the teeth thereof are brought into contact with the bottom surface of the molding cell. The compositions (A) and (B) are moved in a carded fashion. When the comb-like member is moved in the curable compositions (A) and (B) in this manner, the exaggerated expression indicates that the curable composition (A) is present at the mark where the teeth of the comb-like member have passed. Displaced depressions are formed, into which the different-color curable composition (B) of the upper layer flows. This allows the comb The upper layer of the curable composition (B) of a different color penetrates the traces of the teeth of the comb-shaped member up to the bottom of the cell. Will be formed.
図 1は、 上述のように櫛状部材を硬化性組成物中で移動させる工程の一例を示 す模式図である。 図 1に示す例においては、 樹脂粒子を含む硬化性組成物 (A) 2が下層として形成され、 その上に異色の硬化性組成物 (B ) 3がー層、 積層形 成されており、 この両層中に櫛状部材 1の歯の部分を下層の底面まで浸漬し、 歯 の通過跡に上層の異色の硬化性組成物 (B ) 3が底面にまで流れ込むように、 櫛 状部材 1を移動させている。 FIG. 1 is a schematic diagram showing an example of the step of moving the comb-like member in the curable composition as described above. In the example shown in FIG. 1, a curable composition (A) 2 containing resin particles is formed as a lower layer, and a curable composition (B) 3 of a different color is formed on the lower layer to form a laminate. The teeth of the comb-shaped member 1 are immersed in both layers to the bottom surface of the lower layer, and the curable composition (B) 3 of the upper layer having a different color flows into the traces of the teeth so as to flow to the bottom surface. Is moving.
本発明の方法では、 櫛状部材の歯の通過跡に上層の異色の硬化性組成物 (B ) が流れ込むことが必要であり、 ここへ下層部にある硬化性組成物 (A) だけが流 れ込んだのではストライプ柄は形成されない。 したがって、 歯の通過跡に窪みが 形成できることが必要である。 この窪みの発生には、 硬化性組成物 (A) および (B ) の粘度、 櫛状部材の移動速度、 櫛状部材の形状等の種々の因子が相互に関 連している。 したがって、 この窪みをうまく発生するための条件は一律的に定ま るものではなく、 種々の条件に応じて適宜、 決定すればよい。 In the method of the present invention, it is necessary that the curable composition (B) of a different color in the upper layer flows into the trace of passage of the teeth of the comb-like member, and only the curable composition (A) in the lower layer flows there. The stripe pattern is not formed if it is inserted. Therefore, it is necessary that a depression can be formed in the trace of the passage of the tooth. Various factors such as the viscosity of the curable compositions (A) and (B), the moving speed of the comb-like member, the shape of the comb-like member, and the like are interrelated to the occurrence of the depression. Therefore, the conditions for successfully generating the depression are not determined uniformly, but may be determined as appropriate according to various conditions.
櫛状部材の歯の移動速度は、 硬化性組成物 (A) および (B ) の粘度との関係 で重要である。 歯の移動速度が余り遅いと歯の通過跡に窪みができないので、 上 層の異色の硬化性糸且成物 (B ) がセルの底面まで到達できず、 ストライプ柄が形 成できない。 櫛状部材の移動速度としては、 一般的には 1〜: 1 0 c mZ秒程度が 好ましい。 櫛状部材を直線的に移動させて直線的なストライプ柄を形成するのが 一般的であるが、 これを蛇行して移動させて蛇行したストライプ柄を形成するこ ともできる。 櫛状部材は、 複数回移動させることもできる。 複数回移動させると ストライプ柄に揺らぎや間隔に変化が生じ、 自然な趣の人工大理石が得られるの で、 本発明の方法の好ましい態様である。 The moving speed of the teeth of the comb member is important in relation to the viscosity of the curable compositions (A) and (B). If the moving speed of the teeth is too slow, no depression can be formed in the trace of the passage of the teeth, so that the upper layer of the different-color curable yarn (B) cannot reach the bottom of the cell, and a stripe pattern cannot be formed. Generally, the moving speed of the comb-like member is preferably about 1 to 10 cmZ seconds. In general, a comb-shaped member is moved linearly to form a linear stripe pattern, but this can be meandered and moved to form a meandering stripe pattern. The comb member can also be moved multiple times. This is a preferred embodiment of the method of the present invention, because the stripe pattern fluctuates and changes in spacing when moved a plurality of times, and an artificial marble with a natural taste is obtained.
本発明に用いる櫛状部材としては、 硬化性組成物に対して不活性であり、 接着 性を呈さない材料からなるものが適当である。 そのような材料の具体例としては、 アルミニウム等の金属や、 ポリテトラフルォロエチレンでコートされた有機材料 等が挙げられる。 ' ·
図 2は、 本発明に用いる櫛状部材の一例を示す模式図である。 図 2に示す櫛状 部材 4は、 所望の間隔で平行に一列に配列された短冊状の複数の歯 4と、 それら 複数の歯 4の片端を連結する部分から成る。 As the comb-shaped member used in the present invention, a member made of a material that is inert to the curable composition and does not exhibit adhesiveness is suitable. Specific examples of such a material include a metal such as aluminum, an organic material coated with polytetrafluoroethylene, and the like. '· FIG. 2 is a schematic diagram illustrating an example of a comb-shaped member used in the present invention. The comb-shaped member 4 shown in FIG. 2 includes a plurality of strip-shaped teeth 4 arranged in a line in parallel at desired intervals, and a portion connecting one end of the plurality of teeth 4.
櫛状部材の歯の長さは、 上層の硬化性組成物 (B ) に不必要な乱れを生じさせ ないように、 積層された全硬化性組成物の総層よりも、 十分長いものであること が適当である。 また、 歯の幅 (歯の移動方向に垂直な長さ) は、 l〜2 0 mmが 好ましい。 歯の幅は、 形成されるストライプの幅と一致するものではないが、 そ の幅に影響を与える。 歯の厚み (歯の移動方向の長さ) は、 歯の機械的強度が保 たれる厚みであればよく、 ストライプ柄の形成にはあまり影響しない。 歯の断面 形状は、 流線形はあまり適当ではなく、 歯の通過跡の硬化性組成物に乱流が発生 するような角形形状が適当である。 また、 歯の先端の形状は、 成形セル底面に密 着できるように平坦面を有することが好ましい。 多数回の移動をいとわなければ、 歯の本数は 1本でもよく、 所望のストライプ柄に応じて適当な歯の本数おょぴ歯 の間隔を選択すればよい。 The length of the teeth of the comb-like member is sufficiently longer than the total number of layers of the entire curable composition so as not to cause unnecessary disturbance of the upper curable composition (B). Is appropriate. The width of the teeth (the length perpendicular to the direction of movement of the teeth) is preferably l to 20 mm. The width of the teeth does not correspond to the width of the stripe to be formed, but does affect it. The thickness of the teeth (the length in the direction of movement of the teeth) may be any thickness that maintains the mechanical strength of the teeth, and does not significantly affect the formation of the stripe pattern. The cross-sectional shape of the tooth is not very streamlined, and a square shape that generates turbulence in the curable composition in the trace of the passage of the tooth is appropriate. Further, the shape of the tip of the tooth preferably has a flat surface so as to be able to adhere to the bottom surface of the molding cell. If there is no need to move many times, the number of teeth may be one, and an appropriate number of teeth may be selected according to a desired stripe pattern.
本発明においては、 櫛状部材を移動させて硬化性組成物 (A) の層の底面にス トライプ柄を形成した後、 硬化性組成物 (A) および (B ) を硬化させる。 そし て、 この硬ィ匕物を成形セルから取り出して、 人工大理石を得る。 この人工大理石 には、 セル底面との接触面側の表面にストライプ柄が形成されている。 このスト ライプ柄は、 異色の硬化性組成物の流動混合に基づき形成されたものなので、 定 規で線引きしたのとは違つた自然なゆらぎをもったラインのストライプ模様であ る。 さらに、 本発明によれば、 このス トライプの色および柄と、 硬化性組成物 (A) に含まれている榭脂粒子の色およびサイズとの組み合わせにより、 今まで の人工大理石には無い、 全く新しい外観のものを提供することができる。 In the present invention, the curable compositions (A) and (B) are cured after the comb-shaped member is moved to form a stripe pattern on the bottom surface of the layer of the curable composition (A). Then, the hard marriage product is taken out of the molding cell to obtain an artificial marble. The artificial marble has a stripe pattern on the surface in contact with the cell bottom. Since this stripe pattern is formed based on fluid mixing of curable compositions of different colors, it is a stripe pattern of a line having a natural fluctuation different from that drawn by a rule. Furthermore, according to the present invention, due to the combination of the color and pattern of the stripe and the color and size of the resin particles contained in the curable composition (A), An entirely new look can be provided.
以上の説明においては、 主としてバッチ式の注型法による実施形態について説 明したが、 連続式キャスト成形法による方法も可能である。 連続式キャスト成形 法においては、 例えば、 セルとして移動するステンレスベルトとその両側に設'置 されたゴムや樹脂等で作成された硬化性組成物を堰き止めるための枠が使用され る。 すなわち本発明においては、 櫛状部材を静止固定しておき、 ステンレスベル ト側 (成形セル側) を移動させることによって、 櫛状部材が硬化性組成物中を相
対的に移動するようにしてもよい。 In the above description, the embodiment based on the batch-type casting method has been mainly described, but the method based on the continuous-type cast molding method is also possible. In the continuous cast molding method, for example, a stainless steel belt moving as a cell and a frame for damping a curable composition made of rubber, resin or the like provided on both sides thereof are used. That is, in the present invention, the comb-shaped member is stationary and fixed, and the comb-shaped member is moved in the curable composition by moving the stainless steel belt side (molding cell side). You may make it move oppositely.
このようにして得た人工大理石は、 その表面を研削することにより、 よりタリ ァ一な商品価値の高い御影石調の外観を得ることができる。 表面研削の深さは、 添カロした樹脂粒子のサイズによつて異なるが、 最大サイズの粒子の半径以上の深 さで行うことが好ましい。 By grinding the surface of the artificial marble thus obtained, it is possible to obtain a granite-like appearance that is more taller and of higher commercial value. Although the depth of the surface grinding varies depending on the size of the resin particles added, it is preferable to perform the grinding at a depth equal to or larger than the radius of the largest particle.
本発明により得た人工大理石は、 例えば、 住宅におけるキッチン天板、 洗面化 粧台、 パスタブ、 テーブル、 壁材、 家具、 インテリア小物など、 各種の用途に使 用できる。 The artificial marble obtained according to the present invention can be used for various purposes, such as kitchen tops, washstands, passtabs, tables, wall materials, furniture, and interior accessories in houses.
以下、 本発明を実施例により更に詳細に説明するが、 本発明はこれらに限定さ れない。 なお、 以下の実施例において、 シラップには、 メタクリル酸メチル 80 質量%とメタクリル酸メチル重合体 20質量。 /0を混合したものを使用した。 Hereinafter, the present invention will be described in more detail with reference to Examples, but the present invention is not limited thereto. In the following examples, 80% by mass of methyl methacrylate and 20% by mass of methyl methacrylate polymer were contained in the syrup. A mixture of / 0 was used.
[製造例 1 : 白色 1樹脂粒子 (P l、 P 2) の製造] [Production Example 1: Production of white 1 resin particles (Pl, P2)]
表 1記載の配合 1の各成分を混合し、 攪拌しつつ真空脱気した。 この真空脱気 した混合物を、 PVA (ポリビュルアルコール) フィルムを敷いた型枠 (28°C に加熱) 中に注入し、 その上から PVAフィルムを張り付けた。 さらに、 この上 にウレタンマットを載せ、 保温し、 しばらく放置することにより、 シート状の硬 化物を得た。 この硬化物を切断機で小さく切断し、 ハンマーミルで粉碎し、 粉碎 物を篩で分別することにより、 直径 0. 5 mmより大きく 1. 7 mm以下の白色 1 榭脂粒子 (P 1) 、 直径 1mm以上 0.5 mm以下の白色 1樹脂粒子 (P 2) を得た。 The components of Formulation 1 shown in Table 1 were mixed and vacuum degassed while stirring. This vacuum degassed mixture was poured into a mold (heated to 28 ° C) covered with a PVA (polyvinyl alcohol) film, and a PVA film was adhered thereon. Further, a urethane mat was placed thereon, kept warm, and left for a while to obtain a sheet-like cured product. The cured product is cut into small pieces with a cutting machine, ground with a hammer mill, and separated by a sieve to obtain white 1-grease particles (P 1) having a diameter of more than 0.5 mm and not more than 1.7 mm, One white resin particle (P2) having a diameter of 1 mm or more and 0.5 mm or less was obtained.
[製造例 2 : 白色 2樹脂粒子 (P 3、 P4) の製造] [Production Example 2: Production of white 2 resin particles (P3, P4)]
表 1記載の配合 2の各成分を用いたこと以外は、 製造例 1と同様にして、 直径 1.7 mm以上 3.0mm以下の白色 2樹脂粒子 (P 3) 、 直径 0. 1 mm以上 0. 5 mm以下の白色 2樹脂粒子 (P4) を得た。 White resin particles (P 3) having a diameter of 1.7 mm or more and 3.0 mm or less, and a diameter of 0.1 mm or more and 0.5 mm or less in the same manner as in Production Example 1 except for using each component of Formulation 2 shown in Table 1. Thus, white 2 resin particles (P4) having a size of not more than mm were obtained.
[製造例 3 :黒色樹脂粒子 (P 5) の製造] [Production Example 3: Production of black resin particles (P 5)]
表 1記載の配合 3の各成分を用いたこと以外は、 製造例 1と同様にして、 直径 0. 1 mm以上 0. 5 mm以下の黒色樹脂粒子 (P 5) を得た。 Black resin particles (P5) having a diameter of 0.1 mm or more and 0.5 mm or less were obtained in the same manner as in Production Example 1 except that each component of Formulation 3 shown in Table 1 was used.
[製造例 4 :茶色樹脂粒子 (P 6) の製造] [Production Example 4: Production of brown resin particles (P 6)]
表 1記載の配合 4の各成分を用いたこと以外は、 製造例 1と同様にして、 直径
0. 11!1111以上0. 5 mm以下の茶色樹脂粒子 (P 6) を得た。 表 1 (樹脂粒子) Except that each component of Formulation 4 shown in Table 1 was used, the diameter was the same as in Production Example 1. Brown resin particles (P 6) having a size of 0.111! 1111 or more and 0.5 mm or less were obtained. Table 1 (resin particles)
表 2記載の配合 5の各成分を混合し、 攪拌しつつ真空脱気し、 白色 1樹脂粒子 (P 2) 、 黒色樹脂粒子 (P 5) を含む薄い黒色の硬化性組成物 (A1) を調製 した。 また、 表 2記載の配合 7の各成分を混合し、 攪拌しつつ真空脱気し、 白色 の硬化性組成物 (B 1) を調製した。 この 2つの硬化性組成物の粘度は、 何れも 1. 0 P a · sであった。 The respective components of Formulation 5 shown in Table 2 were mixed and vacuum degassed while stirring to obtain a thin black curable composition (A1) containing white 1 resin particles (P 2) and black resin particles (P 5). It was prepared. In addition, each component of Formulation 7 shown in Table 2 was mixed and deaerated under vacuum while stirring to prepare a white curable composition (B1). The viscosity of each of the two curable compositions was 1.0 Pa · s.
上述のようにして調製した硬化性組成物 ( A 1 ) を、 30 c m角のトレィ状成 形セル中に、 厚みが 7mmとなるように層状に注入した。 一方、 硬化性組成物 (B 1) は、 まず、 図 3に示す一つのパーン状容器へ移した。 そして、 この容器 内の硬化性組成物 (B 1) を、 先に注入した硬化性組成物 (A1) 上に、 界面を 崩さないように注入して、 注入厚み 7 mmの上層を積層形成した。 The curable composition (A1) prepared as described above was injected into a 30 cm square tray-shaped molding cell in a layered manner so as to have a thickness of 7 mm. On the other hand, the curable composition (B1) was first transferred to one pan-shaped container shown in FIG. Then, the curable composition (B1) in this container was injected onto the previously injected curable composition (A1) without breaking the interface, and an upper layer having an injection thickness of 7 mm was laminated and formed. .
次いで、 図 2に示した形状の櫛状部材 1を成形セルの一端に浸漬し、 その歯を 成形セルの底面に接触させつつ、 他端へ向けてまっすぐ 50mm/¾>で移動させ た。 この櫛状部材 1は、 厚み 3mmのポリテトラブルォロエチレン板で作製した
ものであり、 歯の幅は 5mm、 歯の間隔は 25mmである。 櫛状部材の移動後、 成形セルに蓋をして、 30分間保温しながら放置することにより、 シート状の硬 化物を得た。 Next, the comb-shaped member 1 having the shape shown in FIG. 2 was immersed in one end of the molding cell, and the teeth were moved at a distance of 50 mm / cm2 toward the other end while contacting the bottom surface of the molding cell. This comb-shaped member 1 was made of a polytetrafluoroethylene plate having a thickness of 3 mm. The tooth width is 5mm and the tooth spacing is 25mm. After the movement of the comb-like member, the molding cell was covered, and left for 30 minutes while keeping the temperature, thereby obtaining a sheet-like cured product.
この硬化物の表面を木工用プレーナ一で 0. 3mm深さに削り、 1 20番、 4 00番、 600番のサンドペーパーで順に研磨したところ、 粒柄とストライプ柄 の両方を有し、 クリア一で商品価値の高い御影石調の人工大理石が得られた。 The surface of this cured product was cut to a depth of 0.3 mm with a woodworking planer and polished with a # 120, # 400, and # 600 sandpaper in order, and had both grain and stripe patterns. First, granite-like artificial marble with high commercial value was obtained.
<実施例 2> <Example 2>
表 2記載の配合 6の各成分を混合し、 攪拌しつつ真空脱気し、 白色 1樹脂粒子 (P l、 P 2) 、 白色 2樹脂粒子 (P 3、 P 4) 、 黒色樹脂粒子 (P 5) 、 茶色 樹脂粒子 (P 6) を含む薄い黒色の硬ィ匕性組成物 (A2) を調製した。 また、 表 2記載の配合 7の各成分を混合し、 攪拌しつつ真空脱気し、 白色の硬化性組成物 (B 1) を調製した。 この 2つの硬化性糸且成物の粘度は、 何れも l. O P a · s であった。 Mix each component of Formulation 6 shown in Table 2 and deaerate while stirring, vacuum 1 resin particles (Pl, P 2), white 2 resin particles (P 3, P 4), black resin particles (P 5) A thin black dangling composition (A2) containing brown resin particles (P 6) was prepared. In addition, each component of Formulation 7 shown in Table 2 was mixed, and the mixture was vacuum-degassed with stirring to prepare a white curable composition (B1). The viscosities of these two curable yarns were both l.OPa · s.
上述のようにして調製した硬ィ匕性組成物 ( A 2 ) を、 30 c m角のトレィ状成 形セル中に、 実施例 1と同様に注入した。 一方、 硬化性組成物 (B 1) も硬化性 組成物 (A2) 上に、 実施例 1と同様にして積層し、 同様に櫛状部材を移動させ、 硬化させ、 プレーナ一で削り、 サンドペーパーで研磨したところ、 粒柄とストラ イブ柄の両方を有し、 微妙な色合い、 深み、 質感のある人工大理石が得られた。 The stiffening composition (A 2) prepared as described above was injected into a 30 cm square tray-shaped molding cell in the same manner as in Example 1. On the other hand, the curable composition (B1) was also laminated on the curable composition (A2) in the same manner as in Example 1, and the comb-like member was moved and cured in the same manner as described above, and was polished with a planar paper. After polishing, artificial marble with both subtle hue, depth, and texture was obtained.
<実施例 3> <Example 3>
まず、 実施例 2と同様にして白色 1樹脂粒子 (P l、 P 2) 、 白色 2樹脂粒子 (P 3、 P4) 、 黒色樹脂粒子 (P 5) 、 茶色樹脂粒子 (P 6) を含む薄い黒色 の硬化性組成物 (A2) を調製し、 この硬化性組成物 (A2) の 2分の 1を取り 分けて、 30 cm角のトレィ状成形型中に、 厚みが 7 mmとなるように層状に注 入した。 First, in the same manner as in Example 2, a thin film containing white 1 resin particles (Pl, P2), white 2 resin particles (P3, P4), black resin particles (P5), and brown resin particles (P6) A black curable composition (A2) was prepared, and a half of the curable composition (A2) was separated and placed in a 30 cm square tray-shaped mold so as to have a thickness of 7 mm. It was poured in layers.
—方、 残りの 2分の 1の硬化性組成物 (A2) に、 着色剤組成物 [白顔料 (ぺ ンカラー製、 商品名 11W1180) 4. 5 gとシラップ 10. 5 gを良く混ぜ合わせた もの] を添加して、 均一に混合し、 白色 1樹脂粒子 (P l、 P 2) 、 白色 2樹脂 粒子 (P 3、 P4) 、 黒色樹脂粒子 (P 5) 、 茶色樹脂粒子 (P 6) を含む灰色 の硬化性組成物 (B 2) を得た。 この硬化性組成物 (B 2) を、 硬化性組成物
(A2) の上に実施例 1と同様にして積層し、 同様に櫛状部材を移動させ、 硬化 させ、 プレーナ一で削り、 サンドペーパーで研磨したところ、 粒柄とストライプ 柄の両方を有し、 微妙な色合い、 深み、 質感のある人工大理石が得られた。 — On the other hand, 4.5 g of white pigment (manufactured by Encolor, trade name: 11W1180) and 10.5 g of syrup were mixed well with the remaining half of the curable composition (A2). ), And mix uniformly, white 1 resin particles (Pl, P 2), white 2 resin particles (P 3, P4), black resin particles (P 5), brown resin particles (P 6) Thus, a gray curable composition (B2) containing was obtained. This curable composition (B2) is used as a curable composition. (A2) was laminated in the same manner as in Example 1, and the comb-like member was moved and cured in the same manner as described in Example 1, and was polished with a sandpaper and polished with sandpaper to have both a grain pattern and a stripe pattern. An artificial marble with subtle shades, depth and texture was obtained.
<実施例 4> <Example 4>
まず、 実施例 2と同様にして白色 1樹脂粒子 (P l、 P 2) 、 白色 2樹脂粒子 (P 3、 P4) 、 黒色樹脂粒子 (P 5) 、 茶色榭脂粒子 (P 6) を含む硬化性組 成物 (A2) を調製した。 この硬化性組成物 (A2) の 2分の 1を取り分け、 こ れに着色剤組成物 [黒顔料 (ペンカラー製、 商品名 11B1513) 0.03 gとシラッ プ 9. 97 gを良く混ぜ合わせたもの] を添加しつつ、 完全には混ざらないよう に 10秒間、 攪拌棒で程よく攪拌し、 不完全混合の硬化性組成物 (A3) を調製 した。 この硬化性組成物 (A3) の外観は、 薄い黒と濃い黒との斑模様を有して いた。 この硬化性組成物 (A3) を、 30 cm角のトレィ状成形型中に、 厚みが 7 mmとなるように、 また、 成形セルに対して層状に一方向へ移動させながら、 注入した。 First, in the same manner as in Example 2, white 1 resin particles (P1, P2), white 2 resin particles (P3, P4), black resin particles (P5), and brown resin particles (P6) are included. A curable composition (A2) was prepared. A half of this curable composition (A2) is taken, and 0.03 g of a colorant composition [black pigment (manufactured by Pencolor, trade name 11B1513) and 9.97 g of syrup are mixed well. While stirring the mixture for 10 seconds with a stirring bar so as not to mix completely, to prepare a curable composition (A3) with incomplete mixing. The appearance of this curable composition (A3) had spots of light black and dark black. The curable composition (A3) was injected into a 30 cm square tray-like mold so as to have a thickness of 7 mm and while being moved in one direction in a layered manner with respect to the molding cell.
一方、 残りの 2分の 1の硬化性組成物 (A2) を用い、 実施例 3と同様にして 灰色の硬化性組成物 (B 2) を得た。 この硬化性組成物 (B 2) を、 硬化性組成 物 (A 3 ) の上に実施例 1と同様にして積層し、 同様に櫛状部材を硬化性組成物 On the other hand, a gray curable composition (B2) was obtained in the same manner as in Example 3 using the remaining one-half curable composition (A2). This curable composition (B 2) was laminated on the curable composition (A 3) in the same manner as in Example 1, and a comb-like member was similarly formed on the curable composition.
(A3) の流れ模様の向きと同じ方向に移動させた。 これを硬化させ、 プレー ナ一で削り、 サンドペーパーで研磨したところ、 粒柄とストライプ柄の両方を有 し、 微妙な色合い、 深み、 質感のある人工大理石が得られた。
It was moved in the same direction as the direction of the flow pattern in (A3). When this was cured, it was ground with a plane and polished with sandpaper. As a result, artificial marble with both subtle colors, depth and texture was obtained, having both grain and stripe patterns.
表 2 (硬化性組成物) Table 2 (Curable composition)
以上説明したように、 本発明によれば、 粒のサイズや色とストライプ柄の色柄 との組み合わせにより、 例えば、 天然の御影石がもつ立体感と質感、 深みのある 色柄を有し、 高級感のある御影石調などの優れた外観を有する人工大理石を、 簡 易かつ良好に製造することができる。 As described above, according to the present invention, the combination of the grain size and color and the stripe pattern color pattern has, for example, a three-dimensional effect and texture of natural granite, a deep color pattern, It is possible to easily and satisfactorily produce artificial marble having an excellent appearance such as a granite-like appearance.
さらに、 このストライプ柄は人工大理石の厚み方向にも連続的に形成されてい るので、 人工大理石の表面を切削しても柄が消失することはない。 また、 櫛状部 材の歯の形態や歯の移動方向等をコントロールすることにより、 ストライプ柄の 幅や走行方向の調製が可能である。 さらに、 人工大理石のベース部分とストライ プ柄部分の成分をほぼ同一にすれば、 柄の付与による人工大理石の機械的物性低 下も無い。
Furthermore, since the stripe pattern is formed continuously also in the thickness direction of the artificial marble, the pattern does not disappear even if the surface of the artificial marble is cut. Further, by controlling the shape of the teeth of the comb-shaped member and the moving direction of the teeth, the width of the stripe pattern and the running direction can be adjusted. Furthermore, if the components of the base portion and the stripe handle portion of the artificial marble are almost the same, there is no reduction in the mechanical properties of the artificial marble due to the provision of the handle.
Claims
1. 直径 0. 1〜 5. 0 mmの樹脂粒子 0. 5〜 30質量%を含む硬化性組 成物 (A) を成形セル内に注入し、 注入した硬化性組成物 (A) の上に異色の硬 化性組成物 (B) を一層以上層状に積層し、 櫛状の部材を、 その歯を前記成形セ ルの底面に接触させつつ積層された硬化性組成物 (A) および (B) 中を移動さ せた後、 硬化させる工程を有する粒柄とストライプ柄の両方を有する人工大理石 の製造方法。 1. Inject a curable composition (A) containing 0.5 to 30% by mass of resin particles having a diameter of 0.1 to 5.0 mm into a molding cell, and place the curable composition (A) on the injected curable composition (A). The curable compositions (A) and (A) are laminated in such a manner that the curable composition (B) of a different color is laminated in one or more layers, and the comb-shaped member is laminated while its teeth are in contact with the bottom surface of the molded cell. B) A method for producing an artificial marble having both a grain pattern and a stripe pattern, having a step of hardening after moving inside.
2. 硬化工程の後、 表面を研削する工程を有する請求項 1記載の人工大理 石の製造方法。 2. The method for producing artificial marble according to claim 1, further comprising a step of grinding the surface after the curing step.
3. 硬化性組成物 (A) および (B) の粘度が 0. 3〜5. O P a · sの範 囲内である請求項 1記載の人工大理石の製造方法。 3. The method for producing artificial marble according to claim 1, wherein the viscosity of the curable compositions (A) and (B) is in the range of 0.3 to 5. OPa · s.
4. 樹脂粒子は、 樹脂組成物を硬化させた後粉碎して得たものである請求 項 1記載の人工大理石の製造方法。
4. The method for producing artificial marble according to claim 1, wherein the resin particles are obtained by curing and then pulverizing the resin composition.
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JP2002183044A JP2004025538A (en) | 2002-06-24 | 2002-06-24 | Manufacturing method for artificial marble having both grain pattern and stripe pattern |
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Citations (4)
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US6306321B1 (en) * | 1997-05-26 | 2001-10-23 | Du Pont-Mrc Co., Ltd. | Method for producing artificial marble having stripe patterns |
JP2001293732A (en) * | 2000-04-12 | 2001-10-23 | Matsushita Electric Works Ltd | Manufacturing method of artificial marble |
US20020011686A1 (en) * | 1998-03-31 | 2002-01-31 | Nobuhiro Mukai | Method of manufacturing artificial marble having stripe pattern |
JP2002036260A (en) * | 2000-07-26 | 2002-02-05 | Matsushita Electric Works Ltd | Method for manufacturing artificial marble |
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JP2975317B2 (en) * | 1996-10-29 | 1999-11-10 | エムアールシー・デュポン株式会社 | Method for producing artificial marble having a stripe pattern |
JPH10180940A (en) * | 1996-12-25 | 1998-07-07 | Nippon Shokubai Co Ltd | Resin molded form having pattern and manufacture of the same |
JP2938008B1 (en) * | 1998-03-31 | 1999-08-23 | エムアールシー・デュポン株式会社 | Method for producing artificial marble having a stripe pattern |
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US6306321B1 (en) * | 1997-05-26 | 2001-10-23 | Du Pont-Mrc Co., Ltd. | Method for producing artificial marble having stripe patterns |
US20020011686A1 (en) * | 1998-03-31 | 2002-01-31 | Nobuhiro Mukai | Method of manufacturing artificial marble having stripe pattern |
JP2001293732A (en) * | 2000-04-12 | 2001-10-23 | Matsushita Electric Works Ltd | Manufacturing method of artificial marble |
JP2002036260A (en) * | 2000-07-26 | 2002-02-05 | Matsushita Electric Works Ltd | Method for manufacturing artificial marble |
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