JPH0437665A - Production of ornamented porous material - Google Patents

Abstract

(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

DETAILED DESCRIPTION OF THE INVENTION (Industrial Application Field) The present invention relates to a method for producing a decorated porous material suitable for use as flooring or walling materials.

(Prior Art) Decorated materials such as artificial marble are used as flooring and wall materials. This type of artificial marble is generally made by mixing inorganic powder and granules with a hardening resin liquid to create a base material of a viscous liquid (paste-like) colored mixture, and a marble pattern is created on the base material of this mixture. It is manufactured by blending pigments of different colors, molding the mixture under normal pressure or pressure, and curing it.

In this case, there is a drawback that the viscous liquid (paste-like) compound is washed away in the mold, and the colored area that should become a marble pattern spreads too thinly, resulting in an unclear marble pattern.

In order to improve such shortcomings, for example,
Japanese Patent No. 13537 proposes a method of making a molding material exhibiting a marble pattern by increasing the viscosity of a compound containing pigments of different colors until it solidifies before the molding and curing step.

Furthermore, Japanese Patent Application Laid-Open No. 57-87913 proposes a method of creating a marble pattern by inserting a spatula or the like coated with pigments of different colors into the base material of a colored mixture before the molding and curing process. There is.

(Problem to be solved by the invention) However, even with such improved conventional methods,
The clarity of the marble pattern has not yet been sufficiently improved, and it lacks the luxurious feel of natural marble. Another problem is that the surface of the resulting artificial marble is substantially smooth, making it slippery especially when wet.

The present invention solves these problems with conventional methods, and its purpose is to provide a clear pattern that is not slippery even when wet, and does not cause stains due to clogging. An object of the present invention is to provide a method for producing a decorated porous material.

(Means for Solving the Problems) The method for producing a decorated porous material of the present invention involves mixing inorganic powder and granules with a curable resin liquid, moistening the material with the resin liquid, and coloring the material in different colors. The method is characterized in that two or more types of powder and granules are prepared separately, and the two or more types of powder and granules are blended and pressure-molded, thereby achieving the above object.

In the present invention, inorganic powders include quartz, kaolin,
Inorganic powders such as clay, silica sand, crushed powder of natural stones such as wollastonite, quartz layer, granite, etc., natural mineral fibers,
Powders of inorganic short fibers such as glass milled fibers, alumina short fibers, potassium titanate short fibers, carbon short fibers, and voice car are used. Note that those with high hardness are preferable.

The maximum particle size of the inorganic powder is preferably 1000 μm or less.

When the maximum particle size exceeds 1000 μm, the pores formed on the surface of the resulting porous material become large, and dirt and the like easily enter the pores and become dirty.

In addition, as the curable resin, unsaturated polyester resin,
Room-temperature-curing or thermosetting resins are used, such as diallyl phthalate resins, epoxy resins, phenolic resins, and acrylic resins, combined with conventional curing agents and catalysts such as organic peroxides, amines, and acid anhydrides. A curing accelerator is added according to the conditions.

The curable resin is used in liquid form, and its viscosity is preferably adjusted to 100 voids or less at room temperature using a solvent or the like. If the viscosity is higher than 100 voids at room temperature, secondary aggregation of the powder particles tends to occur, and the resulting porous material has large and non-uniform pore diameters, making it easy for dirt and the like to enter the pores and become dirty.

When mixing the curable resin liquid with the inorganic powder, the mixing amount is such that the inorganic powder is moistened with the curable resin and maintains the powder state. It is determined by taking into consideration the type and particle size, the type and viscosity of the curable resin liquid, and the pressure molding conditions. Generally, it is prepared in a range of 65 to 85% by weight of the inorganic powder and 35 to 15% by weight of the curable resin liquid. At this time, various desired pigments may be mixed.

In this way, the inorganic granular material is moistened with the curable resin liquid, and two or more types of granular material colored in different colors are individually produced.

Next, these two or more types of colored powders are blended by various methods so as to exhibit a desired pattern.

If a blending method is adopted in which both colored powders are mixed in a simple manner, a dispersion pattern similar to granite can be obtained, for example. Furthermore, if a method of blending is adopted in which one colored powder or granule is partially arranged with the other colored powder or granule, an astronomical stone-like flow pattern or a tile-like checkerboard pattern can be obtained.

The two or more types of colored powders blended in this way are transferred to a desired mold, for example, at a temperature of room temperature to 120°C, 1 to 100°C.
Pressure molding is performed using a press machine or the like at a pressure of 150 kg/crA. In this way, the curable resin is cured, the inorganic powder is bonded with the curable resin, and a decorated porous material having a large number of fine pores formed on the surface is obtained.

(Function) In the method of the present invention, the colored compound of the colored powder and granule formed by mixing the curable resin liquid with the inorganic powder is pressure-molded. Compared to the conventional method of pressure molding a viscous liquid (paste-like) colored compound formed by mixing, the colored compound becomes difficult to flow.

Therefore, patterns formed by two or more types of colored powder particles are less likely to mix together.

Furthermore, when a colored mixture of colored powder and granules as described above is pressure-molded, the inorganic powder and granules are bound by a curable resin, and a large number of fine pores are formed on the surface.

(Example) Examples and comparative examples of the present invention are shown below.

25 parts by weight of a thermosetting epoxy resin liquid (12 voids) colored white by containing 10% by weight of titanium white for coating properties;
Wollastonite (also known as wollastonite, 400 mesh passes)
75 parts by weight were uniformly mixed to prepare a white powder moistened with the resin liquid.

Further, 20 parts by weight of a thermosetting epoxy resin liquid (12 voids) colored black by containing 10% by weight of carbon black and 80 parts by weight of wollastonite (also known as wollastonite, 800 mesh pass) were uniformly mixed, A black powder material moistened with the above resin liquid was prepared.

Next, after spreading the white powder on the surface of a flat mold, grooves were formed using a spatula, the black powder was placed in the grooves, and the mixture was heated at a temperature of 80°C. 100
The resin was cured by press molding at a pressure of kg/C to produce a decorated porous material with a thickness of 41III+.

This porous material has clear patterns, stain resistance,
The slip resistance, pore diameter, and pore volume were measured and evaluated using the following methods. The results are shown in Table 1.

(1) The clarity of the pattern was expressed as ◎ if it was visually clear, ○ if it was somewhat clear, and × if it was unclear.

(2) Stain resistance is determined by talc powder (particle size of 10 μm or less)
is dispersed in water at a ratio of 0.2 g/cc, and 50 cc of this dispersion is sprinkled on the surface of a 100 mm x 100 nv+ porous material, and the case where the talcum powder remains on the surface and can be washed off later is ◎ , The case where the talc powder caused clogging in the pores on the surface was indicated by ×.

(3) Slip resistance was measured by placing a 30 mm x 5 Qg piece of synthetic leather on the surface of a porous material in a wet state, placing a 2 kg load on it, and measuring the friction coefficient using the slope method.
．． 8 or more is represented by ◎, less than 0.8 to 0.6 is represented by ○, and less than 0.6 is represented by ×.

(4) The diameter of the pores is measured using a mercury porosimeter, and ◎ indicates that less than 10% of pores have a pore diameter of 1 μm or more, and 1
More than 10% of pores are larger than μm, and 1 pore is larger than 5 μm in diameter.
A case where the percentage of pores was less than 0% was indicated by ◯, and a case where the number of pores having a pore diameter of 5 μm or more was 10% or more was indicated by ×.

(5) The pore volume is measured with a mercury porosimeter, and ◎ is 0.1 cc/g or more, and ◎ is less than 0.1 to 0.05 cc.
/g is represented by ◯, and less than 0.05 cc/g is represented by ×.

27 parts of a thermosetting unsaturated polyester resin liquid (6 poise) containing 10% by weight of titanium white and colored with white, and mineral fiber (Franklin Fiber: U.S., S.G.
73 parts by weight of 400 Mesosyupus (manufactured by YPSUM) were uniformly mixed to prepare a white powder moistened with the resin liquid.

In addition, thermosetting unsaturated polyester resin liquid (6 poise) colored brown by containing 10% by weight of red pepper (20% by weight)
and alumina hydrate (Hisilite: manufactured by Showa Denko Co., Ltd., 3
00 mesh pass) were uniformly mixed with 80 parts by weight to prepare a brown powder moistened with the resin liquid.

Furthermore, 27 parts of a thermosetting unsaturated polyester resin liquid (6 poise) colored black by containing 10% by weight of carbon blank, and 7 parts of mineral fiber (manufactured by Franklin Huihani USA, S GYPSIIM, 400 mesh pass)
3 parts by weight were uniformly mixed to prepare a black powder moistened with the resin liquid.

Next, the above-mentioned white powder, brown powder, and black powder were easily mixed in a ratio of 2:5:3, spread on a flat mold surface, and heated at 100°C and 80°C. kg
The resin was cured by press molding at a pressure of /ci to produce a decorated porous material with a thickness of 4 decorations.

This porous material has clear patterns, stain resistance,
The slip resistance, pore diameter, and pore volume were measured and evaluated in the same manner as in Example 1. The results are shown in Table 1.

15 parts by weight of a thermosetting unsaturated polyester resin liquid (6 voids) colored black by containing 10% by weight of carbon black and Kansui stone powder granules by the method described in Japanese Patent Publication No. 52-13537. (150 mesh passes) and 85 parts by weight were uniformly mixed to prepare a black paste.

5 parts by weight of a white pigment, titanium white, was mixed with 100 parts by weight of this black paste, and the mixture was left in an oven at 40°C until it thickened and solidified, to produce a marble-patterned molding material.

Next, the above molding material was placed on a flat mold surface, and 10
The resin was cured by press molding at a temperature of 0° C. and a pressure of 80 kg/di to produce an artificial marble with a thickness of 4 m.

Regarding this artificial marble, the clarity of the pattern, resistance to staining,
The slip resistance, pore diameter, and pore volume were measured and evaluated in the same manner as in Example 1. The results are shown in Table 1.

Comparative medicine I By the method described in JP-A-57-87913, 40 parts by weight of a thermosetting unsaturated polyester resin liquid (6 poise) colored white by containing 10% by weight of titanium white and calcium carbonate (150 parts by weight) were prepared. A white paste was prepared by uniformly mixing 60 parts by weight of the following ingredients.

This white paste was placed on a flat mold, and a spatula coated with a thermosetting unsaturated polyester resin liquid containing 10% by weight of black pigment carbon blank was inserted into the mold to mix the black pigment in a flowing pattern.

This was then heated to a temperature of 100°C and a weight of 80 kg/cff.
The resin is hardened by press molding at a pressure of
n artificial marble was manufactured.

Regarding this artificial marble, the clarity of the pattern and the dirt (sa,
The slip resistance, pore diameter, and pore volume were measured and evaluated in the same manner as in Example 1. The results are shown in Table 1.

(Left below) Table 1: It can be suitably used for flooring materials expected to have an anti-slip effect, such as balconies, shower rooms, poolsides, sidewalks, counters, tables, moisture absorbing/releasing wall materials, soundproof building materials, etc.

(Effects of the Invention) As described above, the method for producing a decorated porous material of the present invention uses colored powder as a material during pressure molding, so it does not require the use of conventional liquid (paste-like) colored materials. Compared to the method of pressure molding, patterns are less likely to mix together, and a porous material decorated with clear patterns can be obtained, with a good texture and a luxurious feel. In addition, this porous material has many fine pores on its surface, making it difficult to slip even when wet with water, making it less likely to become clogged.

Claims (1)

[Claims] 1. Mix a curable resin liquid with an inorganic powder and make two or more types of powder and granules that are moistened with this resin liquid and colored in different colors. 1. A method for producing a decorated porous material, which comprises blending and pressure molding.