JPH0696246B2 - Method and device for manufacturing artificial stone having curved or bent line shape on the surface - Google Patents

Description

Description: TECHNICAL FIELD The present invention relates to a method for manufacturing an artificial stone having a curved surface or a bent line on its surface, and an apparatus used directly for carrying out the above manufacturing method.

(Prior art and its problems) Conventionally, a curved surface such as an arc shape, a semi-arc shape, or a V-shape,
Manufacture of artificial stone products, such as artificial marble products, which have a bent line shape such as U-shape, can be performed using a plurality of molds as shown in FIG.
Using a molding die (3) that forms a void (10) having the above shape by combining (3b), the artificial marble molding material (c) prepared in advance is poured into the void to cure the material. This is done by a method in which the mold is disassembled after curing, and the product is taken out after curing.

However, in the above method, the pattern material of the artificial marble molding material flows downward, and the pattern concentrates downward,
Even if an attempt is made to produce a flow-patterned artificial marble, the pattern hangs downward in a parabolic shape, and a satisfactory marble pattern cannot be obtained, and it is also difficult to repeatedly produce a similar pattern to some extent.

On the other hand, with regard to the molding equipment, the molding part of the molding die must be surfaced with strict dimensional accuracy, which makes die manufacturing extremely difficult, and since the mold or FRP mold is used, the mold cost is also low. It is expensive.

(Problems to be Solved by the Invention) The present invention has been made in view of the above problems of the prior art, and an object thereof is to prevent the patterning material in the molding material from flowing downward during molding. Another object of the present invention is to manufacture an artificial stone having a curved surface or a bent line on the surface having a beautiful marble pattern, and to provide a simple apparatus capable of manufacturing the artificial stone.

(Means for Solving the Problems) In order to achieve the above object, in the method for producing an artificial stone having a curved surface or a bent line shape on the surface of the present invention, a gel coat layer is formed on the upper surface, which is placed flat. On the flexible thin plate, the artificial stone molding material is preformed into a plate shape, and after the preformed product is semi-cured, the preformed product together with the thin plate is formed into a molding portion corresponding to the surface shape of the desired product. While moving to another molding die having, and following the molding portion,
The shape of the artificial stone product is formed by pressing it from the side of the preform with an auxiliary die having a pressing portion similar to the forming portion of the forming die.

Further, in the apparatus of the present invention, a forming die having a forming portion formed in a shape corresponding to the surface shape of the product, a flat plate-like temporary receiving plate that is removably arranged above the forming mold, and the temporary receiving upper surface. A flexible thin plate to be placed on a thin plate, a partition frame formed of an elastic material that is temporarily fixed to the peripheral edge of the upper surface of the thin plate, and forms a pool for filling the thin plate with the molding material, and a molding part of the molding die. And an auxiliary mold having a pressing portion similar in shape to the molding portion, which fits into the molding portion.

In the present invention, the bent line means a bent line such as a V-shape or a U-shape.

(Operation) Therefore, according to the above-mentioned configuration of the method of the present invention, the artificial stone is first preformed into a plate shape, and when the preformed product is semi-cured and the molding material loses fluidity, Since it is molded into the shape of the product, the pattern material does not flow down during this molding.

Further, according to the above-described configuration of the device of the present invention, strict dimensional accuracy of the molds for forming the cavity is not required, and the molding mold does not have to be an expensive mold or ERP mold.

(Example) Hereinafter, one example of the present invention will be described with reference to the drawings.

In this example, a plate-shaped flow pattern artificial marble product having a semicircular cross section and having an outer curved surface as a surface is manufactured.

First, the manufacturing apparatus will be described.The manufacturing apparatus includes a molding die (3) in which a semicircular molding portion (2) having a size corresponding to the outer dimension of the surface of the product (d) is provided in the upper surface, and the product (3). A thin plate (1) slightly larger than the expanded size of d), a temporary receiving plate (7) slightly larger than the thin plate (1), and four frame members having a required thickness and length.
A partition frame (9) assembled and formed in (9) and an auxiliary mold (5) are provided.

The above-mentioned forming die (3) has a plurality of plate materials (6) such as plywood which are erected in parallel standing at appropriate intervals with respect to each other.
The molded portion (2 is formed by notching the upper edge of each plate member (6) in a semicircular shape.

The thin plate (1) is preferably made of a synthetic resin plate such as acrylic, or a styrene-resistant material such as a stainless plate, and fits well to the molding part (2), and yet it is between the plate materials (6) of the molding die (3). It is suitable to form it to a thickness of 0.2 to 3.0 m / m so that the bulge at the end is small.

The temporary receiving plate (7) has a thin flat plate guide joint (12) attached to the upper surfaces of a pair of opposing side edges of a rectangular flat plywood, and the inner dimensions of the guide joints (12) are It is formed so as to have substantially the same width dimension as the thin plate (1).

The partition frame (9) is composed of four frame members (9) having a required thickness and length and made of an elastic material such as silicon rubber or foamed polyethylene and having a quadrangular cross section. Along the upper surface of the thin plate (1), a rectangular pool (8) into which the artificial marble molding material (c) described later is poured is formed to a size corresponding to the expanded size of the product (d). .

The auxiliary mold (5) has a holding part (13) for pressing the below-mentioned preform (b) from the back side, and a forming part (2) in which the forming die (3) is recessed in a semicircular shape.
It is formed by projecting or bulging in a semicircular cross section corresponding to the above, and the semicircular arc of the pressing portion (13) is approximately equivalent to the thickness of the product (d) from the diameter of the semicircular arc of the forming portion (2). Small diameter.

The auxiliary mold (5) is made of wood, ERP, rubber hose or the like, and may have a single structure, but has a two-layer structure, that is, a core material and a soft synthetic resin plate or the like wound around the core material. Those are good in molding.

Thus, in order to manufacture an artificial marble product whose surface has a semi-arcuate shape using a cutting device, first, a gel coat layer (a) of an unsaturated polyester resin is applied and cured on one surface of the thin plate (1),
The thin plate (1) is a temporary receiving plate (7) with the gel coat layer (a) facing upward.
It is placed and laid on top, and a partition frame (9) is arranged on the upper surface of the four edges of the thin plate (1), and this is temporarily fixed to the gel coat layer (a) with a tape (4) or the like.

Then, the temporary receiving plate (7) on which the thin plate (1) is placed is molded into the mold (3).
Place on top.

At this time, the temporary receiving plate (7) is arranged such that the lengthwise direction of the guide rod (12) on the upper surface faces the lengthwise direction of the molding portion (2) of the molding die (3).

Next, in the pool (8) surrounded by the partition frame (9) on the upper surface of the thin plate (1),
The artificial marble molding material (c) prepared in advance is poured to form a preform.

The artificial marble molding material (c) is an unsaturated polyester blend for base color (c ₁ ) and an unsaturated polyester blend for pattern (c).
It is obtained by mixing with ₂ ).

The above unsaturated polyester mixture for pattern (c ₂ ) is prepared in one or several kinds, each of which is colored in a different color. (c ₁ ) is appropriately charged into a container and stirred with a spatula to disperse it in the unsaturated polyester admixture for base color (c ₁ ) or the unsaturated polyester admixture for base color (c ₁₎ ) Float almost evenly on the surface without stirring.

Then, this molding material (c) is put into a hopper (16) having a slit-shaped supply port (15), and the above-mentioned supply port (1)
5) While continuously dropping onto the thin plate (1), the hopper (16)
Is moved and poured into the entire area of the pool (8) on the upper surface of the thin plate (1) formed by the mold (9) to be spread.

At this time, the hopper (16) makes the slit direction of the supply port (15) orthogonal to the moving direction of the hopper (16).

As a result, a flow pattern is formed on the preform (b).

The flow pattern may be formed in the length direction or the width direction of the preform.

Next, before the preform is completely cured, exactly when the molding material (c) is semi-cured and its fluidity almost disappears, the temporary receiving plate (7) is placed on the upper surface of the mold (3). Then, the preform (b) is dropped into the molding part (2) of the molding die (3) together with the thin plate (1).

Since the thin plate (1) has flexibility and the partition frame (9) also has elasticity, these are notched-shaped semi-arc-shaped molding portions (6) formed in the respective plate materials (6) constituting the molding die (3). 2)), so that the preform (b) is curved in a substantially semi-circular shape to be curved in a substantially semi-circular shape.

Subsequently, in the previous step, the auxiliary mold (5) was fitted and pressed onto the back side of the preformed product (b) that was dropped into the molding part (2) of the molding die (3) and curved to a semicircle to some extent, Completely align the thin plate (1) and the preform (b) with the forming part (2).

At this time, since the preform (b) is not completely cured yet and has a slight viscosity, it is necessary to prevent the auxiliary mold (5) from adhering to the preform (b). Item (b) and auxiliary type (5)
Although a polyethylene film (17) is interposed between the pressing part (13) and the pressing part (13), it is desirable to apply a release agent to the surface of the pressing part (13).

Then, in this state, the molding material (c) is completely cured,
This is made into a final molded product, that is, a product (d), and when completely cured, first the auxiliary mold (5) is not removed, then the thin plate (1) is separated from the molding mold (2) by the partition frame (9) and the product ( Take out together with d) and remove the partition frame (9) and thin plate (1) from the product (d) without removing the product (d).
To get

Incidentally, in the above embodiment, the manufacture of a plate-shaped product having a semi-arcuate cross-section with the outer curved surface as the surface has been described, but FIGS.
As shown in the figure, by forming a molding portion (2) at the upper edge of each plate material (6) constituting the molding die (3) in a shape projecting in a semi-arc shape contrary to the above embodiment, A product having an inner curved surface as a surface can be similarly manufactured.

In this case, it goes without saying that the holding portion (13) of the auxiliary die (5) is recessed in a semi-circular shape corresponding to the molding portion (2) protruding in a semi-circular shape.

Further, in the above-mentioned embodiment, the plate-shaped artificial marble curved in a semi-circular shape is manufactured, but it is also possible to manufacture the product of the muku-shaped semi-columnar shape as shown in FIG.

That is, in this case, the core material (18) separately formed of concrete, foamed urethane or the like may be adhered to the back side of the product (d) to integrate them, but it is of course possible to use the auxiliary mold (5) as a backup. Molding
When pressing (b) from the back side and moving the preform (b) along the molding part (2), insert a polyethylene film between the auxiliary mold (5) and the preform (b), or press the auxiliary mold. Do not apply release agent to (5), apply adhesive to auxiliary mold (5) on the contrary, perform this step, and use auxiliary mold (5) as core material (18) If the preform (b) is integrally bonded, one process can be simplified. In this case, auxiliary type (5)
Is preferably made of concrete or urethane foam.

Further, as an application of the above-mentioned embodiment, an arc-shaped artificial marble can be manufactured.

That is, in this case, as a molding die (3) as shown in FIG. 12, each plate member (6) is symmetrically arranged at the upper end of each plate member (6).
By fixing plate materials (6) ′ (6) ″ having an equally divided shape with hinges (20) or the like to form an integral structure, the recesses have an arc shape when combined.

The thin plate (1) and the temporary receiving plate (7) are formed to have a size slightly larger than the circular arc-shaped outer peripheral size.

The auxiliary mold (5) has a circular shape as shown in FIG. 12, or a cylindrical shape, and may have a single structure, but it has a two-layer structure, that is, a core material and a soft synthetic resin plate on the outer periphery thereof, etc. The product wound with is excellent in molding.

As the manufacturing method, as shown in Fig. 12, the molding part (2) of the molding die (3)
The thin plate (1) and the preform (b) are dropped into it and the plate materials (6) (6) ′ (6) ″ are combined with each other as shown in FIG. 13, and then the thin plate (1) and the preform (b) are combined. Are joined in an arc shape and the preform is cured to obtain a product as shown in FIG.

In the present invention, the pattern of the artificial stone is not a question, and the method of molding the artificial stone in the step of molding the preform to be formed into a flat plate may be any conventionally known method according to the pattern to be obtained. You can go.

(Effects) The present invention has the following effects because of the above-mentioned configuration.

(1) The method of the present invention preforms an artificial stone into a flat plate shape, and when the preformed product is semi-cured and the fluidity of the artificial stone molding material disappears, the artificial stone product exhibits a curved or bent line shape. The molding part has a curved shape because it is formed into a product shape by following another molding die that has a molding part corresponding to the surface shape, and pressing it from the preform side with an auxiliary mold that has a holding part that is similar to the molding part of the molding die. Or, although it has a bent line shape, there is no downward flow of the patterning material in the molding material during the molding process.

Therefore, the pattern does not appear to be partly offset or sagging, and a stable and beautiful marble pattern is obtained despite the presence of an artificial stone product that has a curved or bent line shape on the surface. be able to.

Moreover, it is possible to integrally form an artificial stone product having a curved or bent line on the surface without working and joining.

(2) The device of the present invention is a molding die having a molding portion formed in a shape corresponding to the surface shape of the product, a plate-shaped temporary receiving plate that is removably disposed above the molding die, and the upper surface of the temporary receiving plate. A flexible thin plate to be placed, a partition frame formed of an elastic material that is temporarily fixed to the peripheral edge of the upper surface of the thin plate and forms a pool for filling the thin plate with a molding material, and a molding part of a molding die. Correspondingly, the molding part and an auxiliary mold having a pressing part of similar shape are fitted to the molding part, so that the artificial stone product having a curved or bent line shape on the surface can be easily carried out by carrying out the method of the present invention. It is possible to manufacture

Moreover, since it is not necessary to use a molding die that combines a plurality of dies to form a cavity or the like having the same shape as an artificial stone product having a curved or bent line shape on the surface, the structure is simple and expensive dies and There is no need to use the FRP type.

In particular, as described in the embodiment section, a plurality of plate materials having a molding part in which a molding die is formed in the upper edge portion in a shape corresponding to the surface shape of the product are arranged in parallel at appropriate intervals. By doing so, it is possible to precisely surface the forming part by simply cutting the required number of plate materials with a saw, manufacturing is easy, and the die cost is low.

[Brief description of drawings]

FIG. 1 is a perspective view of a manufacturing apparatus showing an embodiment of the present invention, FIGS. 2 to 7 are schematic explanatory views showing a manufacturing method according to steps, and FIGS. 2 and 3 are partially cutaway side views. , FIG. 4 is a front view with a part cut away. FIG. 5 FIG. 6 FIG. 7 are vertical sectional front views. FIG. 8 is a perspective view of the product, FIG. 9 is a perspective view showing another example of the product, FIGS. 10 to 11 are vertical sectional front views showing other embodiments, and FIGS. As another embodiment, a front view showing a manufacturing method and a manufacturing apparatus of an artificial marble product having an arcuate surface in the order of steps, FIG. 14 is a perspective view of the product,
FIG. 15 is a perspective view showing an example of a conventional manufacturing method and manufacturing apparatus. a: Gel coat layer, b: Preform, c: Molding material, d: Product, 1: Thin plate, 2: Molding part, 3: Mold, 5: Auxiliary mold, 6: Plate material, 7: Temporary receiving plate, 8 : Pool, 9: Divider frame 13: Presser section

Claims (3)

[Claims] 1. An artificial stone molding material is preformed into a plate shape on a flexible thin plate having a gel coat layer formed on the upper surface thereof, and the preformed product is semi-cured. The preform is moved together with the thin plate onto another forming die having a forming portion corresponding to the surface shape of the desired product, and is imitated by the forming portion, and a pressing portion similar to the forming portion of the forming die. A method for manufacturing an artificial stone in which a curved or bent line is formed on a surface forming an artificial stone product shape by pressing from the side of the preform with an auxiliary mold having a. 2. A molding die having a molding portion formed in a shape corresponding to the surface shape of the product, a flat plate-like temporary receiving plate which is removably arranged above the molding die, and placed on the upper surface of the temporary receiving plate. A flexible thin plate, a partitioning frame made of an elastic material that is temporarily fixed to the peripheral portion of the upper surface of the thin plate and forms a pool for filling the thin plate with the molding material, and the molding part of the molding die. An apparatus for manufacturing an artificial stone having a curved surface or a bent line on the surface, comprising: an auxiliary die having a pressing portion having a similar shape to that of the pressing portion that fits into the pressing portion. 3. A plurality of plate materials, wherein the molding die has a molding portion formed at a top edge portion thereof in a shape corresponding to a surface shape of a product,
An artificial stone manufacturing apparatus according to claim 2, characterized in that they are arranged in parallel at appropriate intervals from each other, and are curved or bent on the surface of the artificial stone manufacturing device. Stone manufacturing equipment.