JPH0724849A - Artificial stone makeup panel manufacturing method - Google Patents

Abstract

(57) [Abstract] [Purpose] An object is to obtain an artificial stone decorative panel that reproduces the texture of natural stone with almost no loss, has no warp, has high strength, and is excellent in waterproofness. [Structure] 10-50 parts by weight of a thermosetting resin having a viscosity of 0.1-3 pa · s at a temperature of 20 ° C., 5-50 parts by weight of crushed stone particles having a particle diameter of 300 μm-5 mm, and A resin composition 2 in which 20 to 65 parts by weight of a transparent powder filler having a particle diameter of 1 to 50 μm is mixed is injected and cured.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing an artificial stone decorative panel used for floors and wall materials for bathrooms, etc., which require waterproofness and dimensional stability.

[0002]

2. Description of the Related Art Conventionally, as a waterproof decorative panel used for bathroom floors, wall surfaces, etc., a mold is made of SMC in which glass fiber, unsaturated polyester, a filler and a coloring material are mixed in a sheet form. Using a method of hot pressing with a press, spraying up glass fiber and unsaturated polyester resin,
Alternatively, a reinforced plastic panel obtained by molding by hand layup.

A decorative panel in which thermosetting resin-impregnated paper obtained by impregnating decorative paper with diallyl phthalate resin, polyester resin or the like is placed on an inorganic board material such as asbestos cement board or calcium silicate board and hot-press molded.

A decorative panel in which the surface of an inorganic plate is subjected to a base color treatment, and then a coating material such as acrylic resin or acrylic urethane resin is applied and the coating film is cured by heating or irradiation with ultraviolet rays.

After undercoating the surface of an inorganic plate material or a reinforced plastics substrate, an aqueous coating material made of acrylic resin emulsion containing colored particles is prepared for each color,
There has been a method of applying a coating using a multi-head spray gun or the like and drying it to form a coating film having a stone pattern.

[0006]

Although the decorative panels manufactured by the conventional manufacturing methods have peculiar characteristics caused by the difference in materials and manufacturing processes, in each method,
It has problems in design, durability, manufacturing process, etc.
It was not always satisfactory.

The reinforced plastics panel formed by molding glass fiber and unsaturated polyester resin is lightweight and has high strength and can easily be applied to various shapes, but it is difficult to form a complicated color pattern such as a stone pattern. It was

In a decorative panel obtained by thermocompressing thermosetting resin-impregnated paper on an inorganic board material such as an asbestos cement board,
Although a desired pattern can be attached to the decorative paper by printing, it was difficult to sufficiently express the texture of the stone material. Further, since the thermosetting resin-impregnated paper has a thin layer, it has a difficulty in abrasion resistance in horizontal applications, and impact resistance is not always satisfactory.

After subjecting the surface of the inorganic plate material to a base coloring treatment,
A decorative panel coated with acrylic resin and cured by UV irradiation has improved surface physical properties compared to the one molded with thermosetting resin-impregnated paper, but it is difficult to express the appearance of stones and the like. , The impact resistance was not sufficient.

In a method of preparing a coating material such as an acrylic emulsion containing colored particles on an inorganic plate material or a reinforced plastics base material for each color and performing spray coating with a multi-head spray gun or the like, design characteristics such as expression of stones are not obtained. Excellent,
The manufacturing process requires manpower and skill, which is problematic in terms of mass productivity.

In addition, even if a resin composition obtained by adding colored resin particles, crushed stone particles, powder filler, etc. to an unsaturated polyester resin is poured into a casting mold, a panel having a stone appearance can be obtained. When crushed stone particles are used, the difference in specific gravity between the resin and the granules is large, so the particles settle to cause uneven dispersion such as layer separation, and as a result, warp of the panel is likely to occur and to prevent warping. Use high viscosity resin,
It has a drawback that defoaming becomes difficult when the compounding amount of the resin is reduced. In particular, this has been a problem for bathroom floor panels and the like that require no warping. Furthermore, aluminum hydroxide powder was generally used as a powder filler, but it impaired the transparency of the resin and could not fully express the texture of natural stone.

It is an object of the present invention to obtain an artificial stone decorative panel which reproduces the texture of natural stone with almost no loss, has no warp, has high strength and is excellent in waterproofness.

[0013]

[Means for Solving the Problems] In the process of injecting a resin composition containing a thermosetting resin, crushed stone particles, and a filler into a casting mold and curing the composition, an artificial stone decorative panel is manufactured. 10-50 parts by weight of a thermosetting resin having a viscosity of 0.1-3 pa · s at 20 ° C., 5-50 parts by weight of crushed stone particles having a particle size of 300 μm-5 mm, and transparency of a particle size of 1-50 μm A method for producing an artificial stone decorative panel characterized by comprising 20 to 65 parts by weight of a powder filler, wherein the thermosetting resin of the resin composition is an unsaturated polyester resin, an unsaturated melamine resin, or methylmethacrylate. The method for producing an artificial stone decorative panel according to claim 1, wherein the transparent powder filler is composed of at least one kind of rate resin, and the transparent powder filler is mainly composed of silica powder.

The casting mold used in the present invention is an open mold made of metal or reinforced plastic. The mold surface has a desired surface finish such as gloss, semi-gloss, and matte finish, and a release agent treatment is performed prior to the casting process.

As the method for treating the release agent, wax, silicone resin or the like is applied and wiped off, or an aqueous polyvinyl alcohol solution is applied and dried to form a film.

The thermosetting resin used in the present invention is a resin such as an unsaturated polyester resin, an unsaturated melamine resin, or a methylmethacrylate resin, or a combination of at least two kinds thereof.

The unsaturated melamine resin of the present invention is a prepolymer having an average molecular weight of 200 to 8000, which is synthesized from melamine, paraformaldehyde, and 2-hydroxyethyl (meth) acrylate by a condensation reaction.

The unsaturated polyester resin in the present invention is obtained by reacting an unsaturated polybasic acid, a resin obtained by heating esterification of a saturated polybasic acid and glycol, or an epoxy resin with (meth) acrylic acid. It is a liquid resin obtained by dissolving the thus obtained vinyl ester resin in a vinyl monomer that acts as a crosslinking agent.

An organic peroxide is used as the curing agent. At room temperature curing, that is, at a relatively low temperature of about 50 ° C. or lower, a substance that decomposes by a catalytic redox reaction and accelerates the generation of radicals is used as a curing accelerator.

As the combination of the curing agent and the curing accelerator in the room temperature curing, an organic acid salt of methyl ethyl ketone peroxide and cobalt, or benzoylperoxide and cobalt naphthenate is generally used.

The thermosetting resin of the present invention at 20 ° C.
Viscosity of 0.1 to 3 pa · s is preferable. If the viscosity is higher than this, if crushed stone particles and powder filler are mixed, it becomes difficult to perform self-leveling and defoaming in the casting process.

As the crushed stone particles, crushed stone materials such as mikage stone, cold water stone, and marble are sized to 300 μm to 5 mm to express the color tone, pattern and other texture of the stone material, and to act as a filler. , Is useful for improving strength. If the particle size is 300 μm or less, the texture of natural stone cannot be obtained, and if it is 5 mm or more, dispersion tends to be difficult. The blending ratio is preferably 5 to 50 parts in terms of texture and leveling property.

As the crushed stone particles, one kind or several kinds are mixed and used depending on the required color tone and texture. If necessary, silane treatment or coloring treatment may be performed to improve the physical properties.

The transparent powder filler of the present invention is a filler which becomes transparent or translucent when dispersed in a thermosetting resin, and is preferably a silica powder having a particle diameter of 1 to 50 μm as a main component, By increasing the viscosity of the resin and preventing the settling of the crushed stone particles, it is possible to maintain the state in which the crushed stone particles are uniformly dispersed in the resin liquid, and to suppress warpage. Further, by using silica powder, it is possible to prevent the generation of air bubbles and pinholes by filling the resin in the gaps between the crushed stone particles. The compounding ratio of silica powder is 20
Appropriate filling properties and fluidity can be obtained in the range of up to 65 parts. All parts in the above formulation represent parts by weight.

The resin composition is usually mixed with a closed stirrer until the materials are uniformly dispersed. It is desirable to perform this stirring while depressurizing and defoaming. The resin composition after stirring is poured into a mold, defoamed by applying vibration or the like, leveling is performed, and then the mold is held horizontally to cure the resin composition. The cured resin composition is demolded from the mold, and after-cured to obtain an artificial stone decorative panel.

[0027]

【Example】

Example 1 An example of the present invention will be described below with reference to the drawings.
FIG. 1 is a cross-sectional view showing an example of a state in which a resin composition 2 is cast in an open type casting mold 1, and FIG. 2 is an example of the material constitution of an artificial stone decorative panel made of the resin composition 2. It is a partial perspective view shown.

A silicone resin mold release material is thinly and uniformly applied to the mold surface of a stainless steel open type casting mold 1 formed in the shape of a floor panel of a unit bath / bathroom. As the resin composition 2 for casting, 6 parts of melamine methacrylic acid prepolymer obtained by condensing melamine, paraformaldehyde and 2-hydroxyethyl (meth) acrylate, fumaric acid, phthalic anhydride, 50% of polyester obtained by condensing isophthalic acid and propylene glycol
Unsaturated polyester 24 consisting of styrene monomer solution
Parts, 0.4 parts of a 55% solution of methyl ethyl ketone peroxide in dibutyl phthalate as a curing agent, and 6 parts of a 6% styrene monomer monomer solution of cobalt naphthenate as a curing accelerator.
The resin liquid is prepared by mixing 2 parts with stirring. The viscosity of this resin liquid at 20 ° C. was 0.7 pa · s.

Next, 15 parts of granulated calcined crushed particles having a particle size of 0.5 mm to 2 mm, 15 parts of cold water stone crushed particles having a particle size of 1 mm to 3 mm, and an average particle size of 6 μm, were added to the prepared resin liquid. 40 parts of silica powder is added, and the mixture is degassed by stirring for 10 minutes while reducing the internal pressure to 13332 pa using a reduced pressure stirring and mixing apparatus, and a uniform resin composition 2 is prepared.

This resin composition 2 was poured into the casting mold 1 so as to have a thickness of 8 mm, vibrated with a vibrator for 2 minutes, defoamed and leveled, and then leveled. It was placed on a table, left to cure at a temperature of 30 ° C. for 2 hours, released from the casting mold 1, and further after-cured in a furnace at 65 ° C. for 2 hours. Open for the cured mold
Pun side surface is AA6 specified in JIS standard R6252
Polishing was performed with an abrasive paper of No. 0 to obtain an artificial stone decorative panel.

The artificial stone decorative panel thus obtained has the deep texture of the stone material, and the crushed stone particles 3 are uniformly dispersed in the thermosetting resin 4 containing the transparent powder filler. It was a sledless one.

Comparative Examples 1 and 2 Comparative Example 1 Without using silica powder as the filler, the average particle size was 10 μm.
An artificial stone decorative panel was manufactured in the same manner as in Example 1 except that 40 parts of aluminum hydroxide of No. 1 was used. As a result, the transparency of the resin was lowered, and the texture of natural stone could not be fully expressed. Example 2 An artificial stone decorative panel was manufactured in the same manner as in Example 1 except that silica powder as a filler was not added. As a result, the crushed stone particles in the resin settled after casting, resulting in non-uniform dispersion,
When it was removed from the mold after curing, warpage was generated in which the resin-rich surface was concave.

[0033]

[Effects of the Invention] Compared to those using aluminum hydroxide as a filler, the transparency is excellent, the deep texture of natural stone can be expressed, and the design effect is enhanced. Also,
Due to the effect of the silica powder as the filler, the resin is filled between the crushed stone particles to suppress the generation of bubbles and pinholes.

Further, from the effect of the balance of the resin composition blending ratio, the fluidity suitable for casting is maintained, and the crushed stone particles do not settle and are hardened in a state of being uniformly dispersed in the resin. Since it does not warp during or after molding, this point is necessary for drainage of the floor material of the bus unit and affects the workability.

[Brief description of drawings]

FIG. 1 is a cross-sectional view showing an example of a state in cast molding of an artificial stone decorative panel of the present invention.

FIG. 2 is a perspective view showing an example of the structure of the artificial stone decorative panel of the present invention.

[Explanation of symbols]

 1 Casting Mold 2 Resin Composition 3 Crushed Stone Particles 4 Thermosetting Resin Containing Transparent Powder Filler

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Claims (2)

[Claims] 1. A resin composition containing a thermosetting resin, crushed stone particles, and a filler is poured into a casting mold and allowed to cure to produce an artificial stone decorative panel. 10 to 50 parts by weight of thermosetting resin having a viscosity of 0.1 to 3 pa · s at a temperature of 20 ° C., 5 to 50 parts by weight of crushed stone particles having a particle diameter of 300 μm to 5 mm, and transparent powder filling of a particle diameter of 1 to 50 μm A method for producing an artificial stone decorative panel, which comprises 20 to 65 parts by weight of an agent. 2. A process for injecting a resin composition containing a thermosetting resin, crushed stone particles, and a filler into a casting mold and curing the resin composition to produce an artificial stone decorative panel, wherein the resin composition is The thermosetting resin is made of at least one kind of unsaturated polyester resin, unsaturated melamine resin, and methyl methacrylate resin, and the transparent powder filler is mainly composed of silica powder. Item 1. A method for manufacturing an artificial stone decorative panel according to item 1.