JP2001071387A - Production of artificial stonel pane, and artificial stone panel - Google Patents

Abstract

PROBLEM TO BE SOLVED: To produce a large-sized artificial stone panel excellent in design effect and having a high grade feeling by eliminating the trouble of an adhesive surface. SOLUTION: An artificial stone panel is produced by a kneading process for charging a matrix material containing a matrix resin and a filler and a granular natural stone in a kneader to obtain a compsn. for the artificial stone panel and a molding process for molding the compsn. for the artificial stone panel to obtain a panel-shaped molded article. In producing a large-sized artificial stone panel having a dimension larger than that of a mold, two or more panel-shaped molded articles obtained by the molding process are bonded by a adhesive and the surface of the bonded article is ground.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

The present invention relates to a method for manufacturing a large artificial slab and a large artificial slab.

[0002]

2. Description of the Related Art Artificial stone slabs are molded products in which a large number of granular natural stones are dispersed in a matrix, and have an appearance that can be easily recognized as high-grade natural stone slabs such as marble and granite. Have been. Unlike natural stone slabs, artificial slabs have the basic properties of excellent heat resistance, high strength such as compressive strength and bending strength, high impact resistance and surface hardness, low water absorption, and low scratch resistance. Boards, counters, vanities, walls,
It is suitably used for floors, partitions, and the like.

[0003] Such an artificial slab is prepared by kneading a matrix material containing a matrix resin and a filler with granular natural stone to obtain a composition for the artificial slab, and preforming the composition for the artificial slab. A molding step of charging the obtained artificial stone slab composition preform into a mold and molding, to obtain a plate-like molded article, and, if necessary, a surface polishing step of polishing the surface of this plate-like molded article And then performing a processing step.

[0004] The size of artificial stone slabs is limited by the dimensions of the current mold, and those exceeding the size cannot be manufactured. May be needed. For example, a mold having a dimension longer than that of the current mold, a mold having a wider width, an L-shaped mold, and the like are used. In the present specification, an artificial stone slab having a size that cannot be manufactured by a mold because it is larger than the dimensions of the existing mold is referred to as a large artificial slab.

[0005] In order to use such a large artificial stone slab, a conventional artificial stone slab manufactured using a current mold is transported to a use site, and then adapted to the situation of the site. Appropriate dimensions were obtained by bonding using an adhesive. However, in such a method, there is a possibility that the resulting large artificial stone plate does not have a uniform basic performance over the entire surface due to incomplete bonding or a defect in the bonding surface. Also,
The adhesive surface became conspicuous, and the pattern of the granular natural stone formed on the surface might not be uniform over the entire surface. As a result, the design and luxury of the artificial slab are often impaired.

[0006]

SUMMARY OF THE INVENTION The present invention has been made in view of the above-mentioned circumstances, and has been made to solve the problem of the adhesive surface.
It is an object of the present invention to provide a method for producing a large artificial stone slab having excellent design properties and a high-quality feel.

[0007]

According to the present invention, there is provided a kneading step in which a matrix material containing a matrix resin and a filler and granular natural stone are charged into a kneading machine to obtain a composition for an artificial slab.
A molding step of molding the composition for an artificial stone plate with a mold to obtain a plate-like molded product, the method for producing an artificial stone plate, comprising: This is a method for manufacturing a large artificial stone plate in which two or more plate-like molded products obtained in the above-mentioned molding step are bonded with an adhesive, and then the surface is polished. The present invention is also a large artificial stone plate manufactured by the method for manufacturing a large artificial stone plate. Hereinafter, the present invention will be described in detail.

The method for producing a large artificial slab of the present invention comprises a kneading step of introducing a matrix material containing a matrix resin and a filler and a granular natural stone into a kneader to obtain a composition for the artificial slab, Molding step of molding the composition for use with a mold to obtain a plate-like molded product.

The above-mentioned matrix material means a composition for forming a matrix of an artificial slab, and the above-mentioned composition is kneaded with a particulate natural stone and then molded to form a matrix as described in detail below. Is what you do. The matrix material contains a matrix resin and a filler.

[0010] The matrix resin contains a thermosetting resin and, if necessary, a low-shrinking agent. The thermosetting resin is not particularly limited as long as it can be used as a molding material. Examples thereof include unsaturated polyester resins, vinyl ester resins (epoxy acrylate resins), (meth) acrylic syrups, diallyl phthalate resins, and the like. Radical polymerization type resins; epoxy resins, urea resins, melamine resins and the like. These may be used alone or in combination of two or more. Among these, unsaturated polyester resins are preferable because the basic performance such as the strength and surface hardness of the artificial stone plate is improved.

The unsaturated polyester resin is not particularly limited. For example, a polymer having a weight average molecular weight (Mw) of several hundreds to several tens of thousands obtained by condensing an acid component and an alcohol component is converted into a vinyl monomer. Examples thereof include a radical polymerization type resin obtained by dissolution. The acid component is not particularly restricted but includes, for example, unsaturated dibasic acids such as maleic acid, maleic anhydride, fumaric acid, itaconic acid, itaconic anhydride, mesaconic acid, citraconic acid, citraconic anhydride; phthalic acid, anhydride Phthalic acid, tetrahydrophthalic acid, tetrahydrophthalic anhydride, hexahydrophthalic anhydride, halogenated phthalic anhydride, isophthalic acid, terephthalic acid, succinic acid, adipic acid, sebacic acid, heptic acid, methyltetrahydrophthalic anhydride, endomethylenetetrahydro Saturated dibasic acids such as phthalic anhydride; and trifunctional or higher polybasic acids such as trimellitic acid, trimellitic anhydride, pyromellitic acid, and pyromellitic dianhydride. These may be used alone or in combination of two or more.

The alcohol component is not particularly restricted but includes, for example, ethylene glycol, propylene glycol, diethylene glycol, dipropylene glycol,
Triethylene glycol, neopentyl glycol,
1,3-butanediol, 1,4-butanediol,
Glycols such as 1,6-hexanediol, bisphenol A, hydrogenated bisphenol A, propylene oxide adduct of bisphenol A, and ethylene oxide adduct of bisphenol A; trifunctional or higher alcohols such as glycerin, trimethylolpropane, and pentaerythritol; Epoxides such as ethylene oxide, propylene oxide, and epichlorohydrin are exemplified. These may be used alone or in combination of two or more.

The vinyl monomer is a reactive monomer, and is not particularly limited as long as it cross-links with the unsaturated group of the polymer at the time of molding. For example, styrene, α-methylstyrene, vinyltoluene, Chlorostyrene, vinyl acetate, allyl alcohol, ethylene glycol monoallyl ether, propylene glycol monoallyl ether, acrylonitrile, maleimides; unsaturated monocarboxylic acids such as acrylic acid, methacrylic acid, crotonic acid, and unsaturated monocarboxylic acids thereof Monoesters of unsaturated dicarboxylic acids such as maleic acid, fumaric acid, itaconic acid and citraconic acid, and monoesters of these unsaturated dicarboxylic acids; ethylene glycol di (meth) acrylate, diethylene glycol di (meth) acrylate, propylene Glycol di (meth) acrylate, dipropylene glycol di (meth) acrylate, neopentyl glycol di (meth) acrylate,
Polyfunctional (meth) acrylates such as trimethylolpropane tri (meth) acrylate and pentaerythritol tetra (meth) acrylate; divinylbenzene, diallyl phthalate, diallyl isophthalate, triallyl cyanurate, triallyl isocyanurate and the like. Further, for example, a (meth) acrylic polymer having an unsaturated group in a side chain, such as obtained by reacting a (meth) acrylic polymer having a carboxyl group with a glycidyl acrylate (meth) acrylate, or the like, may also be used. Can be used. These may be used alone or in combination of two or more.

The types and amounts of the acid component, the alcohol component, and the vinyl monomer in the unsaturated polyester resin are not particularly limited, and may be appropriately set according to the basic performance required of the artificial stone plate. Also,
The method for condensing the acid component and the alcohol component is not particularly limited, and for example, reaction conditions such as a reaction temperature and a reaction time may be appropriately set in the same manner as described above. The polymer may be modified with various components such as a diene compound such as dicyclopentadiene and a rubber component such as a terminal-functional butadiene-acrylonitrile copolymer.

The vinyl ester resin is not particularly limited. For example, radical polymerization obtained by dissolving a reaction product obtained by addition polymerization of a vinyl unsaturated carboxylic acid at the terminal of an epoxy resin into a vinyl monomer is used. Mold resin and the like.

The epoxy resin is not particularly restricted but includes, for example, bisphenol type, novolak type, cycloaliphatic type and epoxidized polybutadiene type.

The vinyl unsaturated carboxylic acid is not particularly restricted but includes, for example, acrylic acid and methacrylic acid. The vinyl monomer is not particularly limited, and includes, for example, styrene, vinyl toluene, methyl methacrylate, vinyl acetate, chlorostyrene, diallyl phthalate, triallyl isocyanurate and the like.
These may be used alone or in combination of two or more.

The types and amounts of the epoxy resin, the vinyl-based unsaturated carboxylic acid and the vinyl-based monomer in the vinyl ester resin are not particularly limited, and may be selected according to the basic performance required for the artificial stone board. What is necessary is just to set suitably. The method of addition polymerization of the epoxy resin and the vinyl unsaturated carboxylic acid is not particularly limited, and for example, reaction conditions such as a reaction temperature and a reaction time may be appropriately set in the same manner as described above.

The (meth) acrylic syrup is not particularly limited, and is, for example, a mixture containing a monomer (meth) acrylate, a polymer of (meth) acrylate, and a crosslinking agent. Yes, as needed
A radical polymerization type resin further containing the above-mentioned vinyl monomer is exemplified.

The above (meth) acrylate is not particularly restricted but includes, for example, methyl (meth) acrylate, ethyl (meth) acrylate, propyl (meth) acrylate, butyl (meth) acrylate, 2-ethylhexyl (meth) acrylate , Lauryl (meth) acrylate, cyclohexyl (meth) acrylate, glycidyl (meth) acrylate and the like. Also,
(Meth) acrylamide can also be used. These may be used alone or in combination of two or more. Among them, methyl methacrylate or (meth) acrylic acid containing methyl methacrylate as a main component, since the basic properties such as weather resistance and surface gloss, appearance, and safety of the artificial stone plate can be further improved. Esters are preferred.

The (meth) acrylic acid ester polymer can be obtained by polymerizing the above (meth) acrylic acid ester and, if necessary, those containing a vinyl monomer as a monomer component. The polymerization degree of the (meth) acrylic acid ester polymer is not particularly limited.

The crosslinking agent is not particularly restricted but includes, for example, ethylene glycol di (meth) acrylate, diethylene glycol di (meth) acrylate, propylene glycol di (meth) acrylate, dipropylene glycol di (meth) acrylate, neopentyl glycol. Multifunctional (meth) acrylates such as di (meth) acrylate, trimethylolpropane tri (meth) acrylate, and pentaerythritol tetra (meth) acrylate; divinylbenzene, diallyl phthalate, diallyl isophthalate, triallyl cyanurate, triallyl isocyanurate And the like. These may be used alone or in combination of two or more.

The (meth) acrylic acid ester, the polymer of the (meth) acrylic acid ester, the crosslinking agent, and the kind and amount of the vinyl monomer used as required in the (meth) acrylic syrup are particularly specified. There is no limitation, and it may be appropriately set according to the basic performance required for the artificial stone slab.

When the thermosetting resin contains two or more kinds of resins and forms a mixture, the content of each resin is not particularly limited. When a radically polymerizable resin is used as the thermosetting resin, a radically polymerizable resin other than the aforementioned radically polymerizable resin may be contained.

The above-mentioned low-shrinkage agent in the above-mentioned matrix resin is not particularly limited as long as it improves the dimensional stability of the artificial stone plate to be obtained. For example, polyethylene, polypropylene, polystyrene, three-dimensionally crosslinked polystyrene, polymethacrylic Examples include methyl acid, polyethylene glycol, polypropylene glycol, cellulose butyrate, acetate (acetylcellulose), polyvinyl chloride, polyvinyl acetate, polycaprolactone, and saturated polyester. These may be used alone,
Two or more kinds may be used in combination. Among these, a saturated polyester is preferable.

The above matrix resin may further contain an additive, if necessary. The additives are not particularly limited, and include, for example, a curing agent, a thickener, an internal release agent, a coloring agent, a chain transfer agent, a polymerization inhibitor, an ultraviolet absorber, a thinner, a coupling agent, an antibacterial agent, and the like. Is mentioned. These may be used alone or in combination of two or more.

The curing agent is not particularly restricted but includes, for example, benzoyl peroxide, lauroyl peroxide, methyl ethyl ketone peroxide, t-butyl peroxy-2-ethylhexanoate, t-butyl peroxy octoate and t-butyl peroxy octoate. Butylperoxybenzoate, cumene hydroperoxide, cyclohexanone peroxide, dicumyl peroxide, bis (4-
t-butylcyclohexyl) peroxydicarbonate, 1,1-bis (t-hexylperoxy) -3,
Organic peroxides such as 3,5-trimethylcyclohexane;
Examples include radical polymerization initiators such as azo compounds such as 2,2'-azobisisobutyronitrile and 2-phenylazo-2,4-dimethyl-4-methoxyvaleronitrile.

The thickener is not particularly restricted but includes, for example, polyvalent metal oxides such as magnesium oxide, calcium oxide and zinc oxide; polyvalent metal hydroxides such as magnesium hydroxide, calcium hydroxide and aluminum hydroxide. Products; polyfunctional isocyanates and the like.

The internal release agent is not particularly limited.
Examples include stearic acid, zinc stearate, aluminum stearate, calcium stearate, barium stearate, stearic acid amide, lauric acid, triphenyl phosphate, alkyl phosphate, and the like. Further, generally used release agents such as waxes and silicone oil can also be used. The colorant is not particularly limited, and includes, for example, inorganic pigments, organic pigments, and toners that can be used in thermosetting resins.

The chain transfer agent is not particularly limited.
For example, α-methylstyrene dimer, carbon tetrachloride, etc.
As a thiol compound, t-butyl mercaptan, n-
Alkyl mercaptans such as octyl mercaptan and n-dodecyl mercaptan; aromatic mercaptans such as thiophenol and thionaphthol; thioglycolic acid; octyl thioglycolate; ethylene glycol dithioglycolate; trimethylolpropane tris- (thioglycolate); Thioglycolic acid alkyl esters such as erythritol tetrakis- (thioglycolate);
β-mercaptopropionic acid; octyl β-mercaptopropionate, 1,4-butanediol di (β-thiopropionate), trimethylolpropane tris- (β
-Thiopropionate) and β-mercaptopropionic acid alkyl esters such as pentaerythritol tetrakis- (β-thiopropionate).

The polymerization inhibitor is not particularly limited.
For example, pt-butylcatechol, p-methoxyphenol, hydroquinone, p-benzoquinone, chloranil, m-dinitrobenzene, nitrobenzene, p-phenyldiamine, sulfur, diphenylpicrylhydrazyl,
Di-p-fluorophenylamine, tri-p-nitrophenylmethyl and the like.

The ultraviolet absorber is not particularly limited, and for example, those which can be used for thermosetting resins such as benzophenone type and benzotriazole type can be used. The viscosity reducing agent, the coupling agent, and the antibacterial agent are not particularly limited, and for example, those that can be used for a thermosetting resin can be used.

The filler in the present invention preferably contains aluminum hydroxide as an essential component, and may contain other components, since the basic performance such as the strength of the artificial slab is improved. The other components are not particularly limited, and include, for example, inorganic materials such as calcium carbonate, calcium sulfate, barium sulfate, alumina, clay, talc, milled fiber, silica (silica sand), river sand, diatomaceous earth, mica powder, gypsum, and glass powder. Fillers: organic fillers, fiber reinforcing materials and the like. These may be used alone or in combination of two or more.

The fiber reinforcing material is not particularly limited.
For example, inorganic fibers such as glass fibers, carbon fibers, metal fibers, and fibers made of ceramic; organic fibers made of aramid, polyester, and the like; and natural fibers. Further, the form of these fibers is not particularly limited, and examples thereof include roving, chopped strand, mat, cloth (woven fabric), and the like.

[0035] The granular natural stone in the present invention is not particularly limited as long as the natural stone is granulated. Also,
Pottery, porcelain, glass, stationary glass, and the like can also be used.

The material of the natural stone is not particularly limited, and includes, for example, igneous rocks such as granite and andesite; sedimentary rocks such as sandstone and tuff; metamorphic rocks such as marble, slate, and serpentine; No. These may be used alone or in combination of two or more. Among them, granite is preferable because the artificial stone plate has excellent surface hardness and chemical resistance. The granite is not particularly limited, and examples thereof include granites such as Fujioka Mikage and Manari Mikage, mahogany, Belfast, Verdefontan and the like.

The particle size range of the granular natural stone is not particularly limited, and is preferably 30 mm or less, more preferably 1 to 15 mm. If it exceeds 15 mm, there is a possibility that breakage and abrasion of the granular natural stone cannot be suppressed in the kneading step. Moreover, there is a possibility that the kneading machine may be damaged. Furthermore, since the fluidity of the composition for artificial slabs is inferior, workability at the time of production is reduced, and filling in a mold in a molding step may be insufficient. Further, the maximum particle size is preferably 20 mm or less. More preferably, it is 13 mm or less.

The particle size distribution of the granular natural stone is not particularly limited. For example, when forming a plate having a thickness of 13.5 mm, the following particle size distribution is preferable. Particles having a particle size of 6 mm or more: 0 to 15% by weight Particles having a particle size of 5 mm to less than 6 mm: 0 to 30% by weight Particles having a particle size of 4 mm to less than 5 mm: 5 to 30% by weight Particles having a particle size of 3 mm to less than 4 mm: 5 Particles having a particle size of 2 to less than 3 mm: 10 to 50% by weight Particles having a particle size of 1 to 2 mm: 5 to 50% by weight Particles having a particle size of less than 1 mm: 0 to 10% by weight The total amount is 100% by weight.

If the distribution of the particles having a particle size of 5 mm or more exceeds the above range, there is a possibility that in the kneading step, breakage and abrasion of the particulate natural stone cannot be suppressed. Moreover, there is a possibility that the kneading machine may be damaged. Furthermore, since the fluidity of the composition for artificial stone slabs is inferior, the workability at the time of production is reduced, and the filling in the mold may be insufficient. 10% by weight of particles having a particle size of less than 1 mm
When it exceeds, blackening may occur on the artificial stone plate. When the distribution of particles having a particle size of 1 mm or more and less than 5 mm exceeds the above range, the particle size distribution becomes nearly uniform, so that the pattern of the granular natural stone formed on the surface of the artificial stone plate may be difficult to approximate natural stone. .

The average particle size of the granular natural stone is not particularly limited, but is preferably 3 to 8 mm. 3m
When it is less than m, the particle size distribution becomes nearly uniform, and the pattern of the granular natural stone formed on the surface of the artificial stone plate may be difficult to approximate natural stone. If it exceeds 8 mm, there is a possibility that breakage or abrasion of the granular natural stone cannot be suppressed in the kneading step. Moreover, there is a possibility that the kneading machine may be damaged. Furthermore, since the fluidity of the composition for artificial slabs is inferior, workability during production is reduced,
In the molding step, there is a possibility that filling in the mold may be insufficient. More preferably, it is 4 to 7 mm. The type of the particulate natural stone and the state of the particles are factors that determine the appearance and basic performance of the artificial stone plate of the present invention, and can be appropriately selected according to the use of the artificial stone plate to be obtained.

In the present specification, the maximum grain size of the granular natural stone is defined as the maximum grain size b which is obtained by passing through a sieve having a mesh size of (b + d) mm (where d> 0) and remaining in the bmm sieve.
mm. In the present specification, the particle size distribution of the granular natural stone means, for the granular natural stone before being put into the kneading machine, means the distribution of the particle size of each particle constituting the granular natural stone, the horizontal axis is the particle size, the vertical axis Can be expressed by the weight ratio (% by weight) of the particles having each particle size. The particle size distribution can be measured according to the sieving method of JIS Z8815. In the present specification, the average particle size means a representative particle size. In the case where the horizontal axis represents the particle size and the vertical axis represents the weight ratio (% by weight) of the particles having each particle size, and represents the particle size distribution of the granular natural stone, the direction of the particle size increases from the minimum particle size. The weight ratio (% by weight) of each particle size is accumulated, and the total is 50% by weight.

In the method for producing an artificial stone slab, the types and amounts of each component in the matrix resin, the filler and the granular natural stone, the combination thereof, molding conditions for forming the artificial slab, or the artificial slab May be appropriately set in accordance with the basic performance required for the above, its use, and the like, and there is no particular limitation.

The amount of use of the above-mentioned low shrinkage agent in the above-mentioned matrix resin is preferably from 0 to 50 parts by weight based on 100 parts by weight of the thermosetting resin. If it exceeds 50 parts by weight, the basic performance such as the strength of the artificial slab may be reduced. The amount of the thickener used in the matrix resin can be appropriately set according to the weight average molecular weight and the viscosity of the thermosetting resin.

The amount of the filler used is preferably 30 to 300 parts by weight based on 100 parts by weight of the matrix resin. When the amount is less than 30 parts by weight, the basic performance such as the strength of the artificial slab may be reduced. There is.
In the filler, the aluminum hydroxide is preferably 50 to 100% by weight based on the total amount of the filler. When the content is less than 50% by weight, the basic performance such as the strength of the artificial stone plate may be reduced. More preferably, 70
１００100% by weight.

It is preferable that the amount of the granulated natural stone used is 50 to 1000 parts by weight based on 100 parts by weight of the matrix resin. When the amount is less than 50 parts by weight, the basic performance such as strength and surface hardness of the artificial stone plate and the design may be deteriorated. When the amount exceeds 1000 parts by weight, the fluidity of the composition for the artificial stone plate is inferior. The filling property may be reduced. More preferably, 300
８００800 parts by weight.

The production of the artificial slab is carried out by kneading a matrix material containing a matrix resin and a filler and granular natural stone into a kneader to obtain a composition for the artificial slab, and
A molding step of molding the composition for artificial stone slabs with a mold to obtain a plate-like molded product, and, if necessary, a surface polishing step of polishing the surface of the molded product. In molding the above-described artificial stone sheet composition with a mold, a pre-molding step may be included, if necessary, so that the artificial stone sheet composition obtained by pre-molding the artificial stone sheet composition is molded using a mold. It is preferred to mold with.

The kneading step is performed in order to obtain a composition for an artificial stone plate by sufficiently kneading the components constituting the matrix material and the particulate natural stone to disperse the granular natural stone in the matrix material. The composition for an artificial slab is obtained by the kneading step, and is a composition in which the above-described components are kneaded.

In the kneading step, for example, first, a part or all of the matrix resin is prepared with a stirrer such as a disper, then put into a kneader such as a kneader and kneaded, and then the remaining components are sequentially kneaded with a kneader or the like. Kneading with a machine can be performed.

The type of the kneading machine such as the above kneader is not particularly limited, and examples thereof include a sigma blade type and a Banbury type. The matrix material is obtained by shaving the kneading blade of the kneader or the inner wall of the container. In order to suppress darkening, it is preferable that a ceramic chip is attached to the kneading blade and the inner wall of the container.

The rotational speed and temperature of the kneader in the kneader such as the above kneader are not particularly limited. However, in order to sufficiently knead the matrix material and the particulate natural stone, the rotational speed is 20 to 50 rpm and the temperature is 10 to 60 ° C. It is preferable to set More preferably, the temperature is 15 to 40 ° C
It is. In the kneading step, the order of charging the above-described components to the kneader and other kneading methods are not particularly limited.

In the forming step in the present invention, the artificial stone slab composition is preliminarily molded, if necessary, and the artificial stone slab composition preform is charged into a mold and molded. This is performed to obtain a molded product.

In the present specification, the preforming means a composition for artificial stone slab obtained in a kneading step in order to facilitate charging of a mold and to improve the filling property of the composition for artificial slab. For example, the method is performed by preform packing in which the composition for artificial slabs is packed in a container or the like, or by extruding with an extruder.

The preform of the composition for artificial stone board is obtained by the preform. The composition for artificial stone slabs and the preform of the composition for artificial stone slabs are usually also referred to as bulk molding compound (BMC).
The method of packing the preform is not particularly limited,
For example, it may or may not be aged at room temperature.

In the above-mentioned molding step, for example, after charging the preform of the composition for artificial stone plate into a heated mold, the mold is pressurized to thereby form a lower mold (lower mold) and an upper mold (upper mold). ), The preform of the artificial stone slab composition is spread and filled in a mold, and can be performed by pressure molding such as press molding (compression molding) in which the composition is held for a predetermined time.

The dimensions of the mold are not particularly limited.
For example, the height is 500 to 1000 mm and the width is 2000 to 4
Thicknesses of about 000 mm are preferably applied. In this specification, the dimension of the mold means the dimension of the cavity portion of the mold.

In the present specification, charging the artificial stone slab composition into a mold means disposing the artificial slab composition on a lower mold (lower mold). The method for arranging the composition for artificial stone slabs is not particularly limited. The above-mentioned mold can be charged by a BMC charge machine or the like, and the molded plate-like molded product can be taken out of the mold by a product take-out machine or the like. The pressurization of the mold can be performed, for example, at a pressure of 50 to 200 kgf / cm ² .

The heating temperature of the mold is not particularly limited, but is preferably from 100 to 170 ° C. Further, the upper mold and the lower mold may be at the same temperature or different temperatures. The molding time during which the mold is pressed is not particularly limited, but is preferably 180 to 700 seconds. Heating temperature is less than 100 ° C or molding time is 1
If the time is less than 80 seconds, the composition of the artificial stone plate may be insufficiently cured, and if it exceeds 700 seconds, it is not economical. If the heating temperature exceeds 170 ° C., the basic performance, design, and luxury of the artificial slab may be reduced.

In the surface polishing step in the present invention, for example,
In the same manner as in the surface polishing step of natural stone, the polishing can be performed by continuous polishing or uniaxial polishing of the surface of the plate-like molded product obtained in the molding step by a wet polishing machine. The thickness to be polished by the surface polishing step is not particularly limited. For example, the pattern of the granular natural stone in the matrix in the obtained artificial stone plate becomes clearer than that before the surface polishing step, and the design property is improved. It is preferable to set it to about 0.5 to 2.0 mm.

According to the method for manufacturing a large artificial stone slab of the present invention, in manufacturing a large artificial stone slab having a size larger than that of the mold, two or more plate-like molded products obtained in the molding step are bonded with an adhesive. Then, the surface is polished.

In manufacturing a large artificial stone slab having a size larger than the above-mentioned mold, an artificial stone slab manufactured using a current mold is transported to a use site, and then an adhesive is used according to the situation at the site. If the measures are taken by bonding, the bonding will be incomplete or defects will remain on the bonding surface.
In addition, the adhesion surface becomes more conspicuous, and the pattern of the granular natural stone formed on the surface is not uniform over the entire surface. Further, the same applies to the case where the surface is polished only at the place where it has been bonded, if necessary. For this reason, the obtained large artificial stone plate may not have uniform basic performance on the bonding surface, and the design property and high-grade feeling peculiar to the artificial stone plate may be impaired by the presence of the bonding surface.

In manufacturing a large artificial stone plate having a size larger than that of the above-mentioned mold, if the incomplete bonding and the failure of the bonding surface are suppressed, the obtained large artificial stone plate has a uniform basic It has performance. Further, when the bonding surface becomes less conspicuous, the pattern of the granular natural stone formed on the surface becomes uniform over the entire surface, and the design properties and luxury feeling peculiar to the artificial stone plate are prevented from being impaired.

The present inventors have conducted intensive studies and as a result, when producing a large artificial stone plate having a size larger than the above-mentioned mold,
The two or more plate-like molded products obtained by the above-mentioned molding process are adhered with an adhesive, and thereafter, the surface is polished to eliminate defects in the adhered surface. It has been found that a large artificial slab having high quality and high quality can be obtained, and the present invention has been completed. The manufacture of such large artificial stone slabs
The kneading step, the forming step, and the surface polishing step performed as necessary can be performed consistently in a manufacturing plant. As described above, it is not clear why the idea of performing the above-mentioned bonding process consistently in a manufacturing factory has not existed until now, but large artificial slabs are generally inconvenient for transportation and work. It may have been repelled for vague reasons. The inventors of the present invention have conceived of the present invention that can increase the commercial value extremely economically with a small amount of contrivance.

In the present specification, “excellent in design”
And, the granular natural stone dispersed in the matrix,
By exhibiting various colors, shapes, patterns, and the like, it is meant that the appearance of the artificial stone plate such as a pattern or pattern formed on the surface gives a good impression to a viewer. In addition, "having a high-class feeling" means that the particulate natural stone dispersed in the matrix,
By the matrix having sufficient transparency, it means that the same high-grade feeling as natural stones such as granite and marble inherent to the granular natural stones appears on the surface of the artificial stone plate.

The idea of bonding with an adhesive to manufacture a large artificial slab is not a new idea. Even if two or more natural slabs are glued together to obtain a large natural slab, it will no longer be a natural product, so its value as a natural slab will be lost, and the pattern of the natural slab will be different For this reason, if two or more natural stone boards are bonded together, the bonding surface becomes conspicuous.Therefore, it is not possible to attach two or more natural stone boards with an adhesive to give the same design and luxury as non-bonded natural stone boards. Can not. On the other hand, in the case of an artificial stone slab, the value obtained by bonding two or more objects with an adhesive does not decrease its value unlike a natural stone slab. In addition, when the adhesion is incomplete or defects on the bonding surface are suppressed, the artificial stone slab is less likely to be unnatural on the bonding surface due to the appearance of a fixed pattern. The large artificial stone slab obtained does not have a noticeable adhesive surface, and the design and luxuriousness are not reduced.

In producing a large artificial stone plate having a size larger than the above-mentioned mold, two or more plate-like molded products obtained in the above-mentioned molding step are adhered with an adhesive, and then the surface is polished. The following are conceivable reasons why it is possible to obtain a large artificial stone slab having the basic performance uniform over the entire surface, having excellent design properties, and having a sense of quality by eliminating defects. That is, after transporting the artificial stone slab manufactured using the current mold to the site of use, gluing it using an adhesive according to the situation at the site, and further performing surface polishing at the site as necessary If you deal with it, you can not stably bond due to the skills of the bonding technician,
Insufficient bonding or defects on the bonding surface will remain, and the wet polishing machine cannot be brought to the site of use and the entire surface cannot be polished. Although the handle of the granular natural stone formed on the surface is not uniform over the entire surface, it is dealt with by bonding the two or more plate-like molded products obtained by the above-mentioned molding process with an adhesive and performing surface polishing over the entire surface. Then, the variation in quality caused by the bonding technician is reduced, and bonding can be stably performed. For this reason, incomplete bonding and defects remaining on the bonding surface are suppressed. Further, since the surface can be polished over the entire surface by the wet polishing machine, the bonding surface becomes less noticeable, and the pattern of the granular natural stone formed on the surface becomes uniform over the entire surface.

The two or more plate-like molded products obtained by the above-mentioned molding step are not particularly limited. For example, the plate-like molded product obtained by the above-mentioned molding step may be used as it is, or a wet diamond cutter, Using a general natural stone processing tool such as a chamfering machine or a water jet, a tool subjected to processing such as cutting and drilling may be used, or a combination of these tools may be used. Further, the substrate may or may not have undergone the above-mentioned surface polishing step. However, it is preferable that the substrate has been subjected to the surface polishing step since the production efficiency is better if the production is performed up to the surface polishing step. Furthermore, when a broken material generated by performing processing such as cutting on a plate-like molded product is used, the broken material can be effectively used, and the production cost can be suppressed. The number of the plate-like molded products is not particularly limited, and for example, is preferably 2 to 6 in consideration of the efficiency of bonding the plate-like molded products.

The above-mentioned adhesive is not particularly limited, and examples thereof include a cyanoacrylate instant adhesive, an epoxy resin adhesive, a polyester resin adhesive, a polyurethane resin adhesive, a vinyl acetate resin adhesive, and a silicone resin adhesive. Synthetic resin-based adhesives such as adhesives and synthetic rubber-based adhesives; inorganic adhesives such as cement-based adhesives and ceramic-based adhesives; Further, the adhesive may be a reactive adhesive or a non-reactive adhesive, and may be a solvent-based adhesive or an emulsion-based adhesive. Further, a hot melt adhesive or a film adhesive may be used. Among these, cyanoacrylate-based instant adhesives are preferred because they improve the production efficiency and can stably adhere by suppressing incomplete adhesion or remaining defects on the adhesion surface.

The method of bonding the two or more plate-like molded products obtained in the above-mentioned molding process with an adhesive is not particularly limited as long as it is appropriately set according to the kind of the adhesive to be used. For example, as a method for treating the bonding surface of two or more plate-like molded products, the bonding surface may or may not be polished, but it is preferable to polish the bonding surface so as to be smooth. Also,
The adhesive can be applied by a roller, a brush, a tube, or the like. Further, the adhesive can be dried by natural drying, forced drying, or the like.

The two or more plate-like molded products obtained by the above-mentioned molding step are bonded with an adhesive, whereby the two or more plate-like molded products are bonded to each other. Is formed. The thickness of the bonding surface is not particularly limited. For example, in order to make the bonding surface less conspicuous, and to suppress a decrease in the design and luxury of the large artificial stone plate, the thickness is set to 5 to 50 μm. preferable. More preferably, it is 10 to 30 μm.

The above-mentioned surface polishing is preferably performed uniformly over the entire surface, since the adhesion surface becomes less noticeable and the pattern of the granular natural stone formed on the surface becomes uniform over the entire surface. The method for performing the surface polishing is not particularly limited as long as the method can perform the surface polishing over the entire surface. For example, since the method can be performed uniformly over the entire surface, continuous polishing or single-axis polishing using a wet polishing machine is performed. It is preferable to carry out. As the wet polishing machine, a wet flat polishing device for natural stone can be used.

The thickness to be polished by the surface polishing is not particularly limited, and is preferably, for example, about 5 to 1000 μm. If it is less than 5 μm, it may not be possible to uniformly polish the surface over the entire surface.
If it exceeds 000 μm, the thickness of the artificial slab may be too thin. More preferably, it is 10 to 50 μm.

An example of the method for producing a large artificial slab of the present invention will be described in detail. For the two or more plate-like molded products obtained in the above-mentioned molding process, the surface is polished by a wet polishing machine to obtain a surface-polished plate-like molded product by performing the surface polishing step, and cutting and drilling are performed as necessary. And so on. This surface is polished, two or more plate-shaped moldings processed as necessary are arranged so that the bonding surfaces face each other, an adhesive is applied to the bonding surface of one or both plate-shaped moldings, and pressed by the bonding surface. After bonding, a large artificial stone plate can be obtained by uniformly polishing the surface over the entire surface with a wet polishing machine.

The large artificial stone plate of the present invention can be cut, drilled, and joined by using a general natural stone processing tool such as a wet diamond cutter, a chamfering machine, or a water jet, or an adhesive that can be used for natural stone. In addition, a processing step and a construction step for performing bonding and the like can be performed.

The large artificial slab of the present invention is manufactured by the above-described method for manufacturing a large artificial slab of the present invention. In the large artificial slab of the present invention, the amount of the granular natural stone dispersed in the matrix is preferably 30 to 90% by weight based on the total amount of the artificial slab. When the content is less than 30% by weight, the basic performance such as the surface hardness of the artificial stone plate may be reduced, or the design of the granular natural stone formed on the surface of the artificial stone plate may be reduced, so that the design property may be reduced. If it exceeds 90% by weight, the fluidity when molding the composition for artificial slate may be reduced.
Further, basic performance such as the strength of the artificial slab may be reduced.

The shape and dimensions of the large artificial slab of the present invention are not particularly limited as long as it is larger than the mold. And the like. The shape of the two or more plate-like moldings forming the large artificial stone plate of the present invention is not particularly limited.For example, in the case of a large artificial stone plate longer than the size of a mold, a long object or a normal size In the case of a large artificial stone plate wider than the size of the mold, it is only necessary to combine long objects with different widths, and in the case of an L-shaped large artificial stone plate, , A rectangular trapezoidal long one, a normal rectangular trapezoidal one, etc. may be combined. The large artificial stone slab of the present invention is excellent in heat resistance, and has high strength such as compressive strength and bending strength, because the large artificial stone slab having a size larger than the mold is wiped out of defects in the bonding surface. Excellent design with high impact strength and high surface hardness, low water absorption, low scratch resistance, and sufficient basic performance, and the pattern of granular natural stone formed on the surface is uniform over the entire surface Even if granite, granite, marble, or any other natural stone is used as the granular natural stone, the high-grade feel of the natural stone can be exhibited on its surface, and tiles, wall panels, etc. Architectural decoration materials; bathtub (bathtub),
Vanity table (counter), sink (sink), bathroom panel, system kitchen top plate (kitchen counter),
Housing equipment such as table tops and the like, which can be suitably applied to various decorative articles, nameplates and the like.

[0076]

The present invention will be described in more detail with reference to the following examples, but the present invention is not limited to these examples. Note that “parts” indicates “parts by weight”.

Preparation Example 1 In a four-necked flask as a reactor equipped with a thermometer, a nitrogen gas inlet tube, and a stirrer, 980 parts of maleic anhydride as α, β-unsaturated dibasic acid, After charging 3,360 parts of ethylene oxide 2-adduct of bisphenol A as a polyhydric alcohol, the inside of the flask was replaced with nitrogen gas. Next, the mixture was stirred while the maximum temperature was 215.
C., and the dehydration reaction was performed for a predetermined time. Thus, an unsaturated polyester having an acid value of 17 was obtained. Then, resin A-1 was obtained by mixing 70 parts of this unsaturated polyester, 30 parts of styrene as a vinyl monomer, and 0.02 parts of hydroquinone as a stabilizer.

Preparation Example 2 Thermometer, nitrogen gas inlet tube,
In a four-necked flask as a reactor equipped with a stirrer, 1660 parts of isophthalic acid as a saturated dibasic acid and 1380 parts of dipropylene glycol as a polyhydric alcohol were placed.
After charging the parts, the inside of the flask was replaced with nitrogen gas. Next, the mixture was heated to a maximum temperature of 215 ° C. while stirring, and a dehydration reaction was performed for a predetermined time. As a result, a saturated polyester having an acid value of 12 was obtained. Then, 60 parts of this saturated polyester, 40 parts of styrene as a vinyl monomer, and 0.1 part of hydroquinone as a stabilizer were added.
By mixing 02 parts, resin B-1 was obtained.

Example 1 As a thermosetting resin, an unsaturated polyester resin A-
185 parts, 15 parts of saturated polyester resin B-1 as a low-shrinking agent, KBM-5 as a coupling agent
2.0 (trade name, manufactured by Shin-Etsu Chemical Co., Ltd.), 0.5 part of α-methylstyrene dimer as a chain transfer agent, and Tinuvin 320 (trade name, manufactured by Ciba Specialty Chemicals) as an ultraviolet absorber. 5 parts, 0.1 part of parabenzoquinone as a polymerization inhibitor, and 0.3 toner AT-3 (trade name, manufactured by Dainichi Seika Co., Ltd.) as a colorant
The mixture was charged into a container and stirred by a disper for 10 minutes. Thereafter, Perhexa TMH (trade name,
2.0 parts (manufactured by NOF Corporation) was added, and the mixture was further stirred for 10 minutes by a disper to prepare a matrix resin.

Next, the total amount of the prepared matrix resin,
Heidilite H which is aluminum hydroxide as filler
200 parts of -320 (trade name, manufactured by Showa Denko KK) and 250 parts of Fujioka Mikage as granular natural stone were put into a kneader in which a ceramic chip was adhered to a kneading wing and the inner wall of a container, and the kneader was rotated and kneaded for 1 minute. Thereafter, with the kneader rotated, 20 parts of chopped strand ECS06B-144 / P (trade name, manufactured by Nippon Electric Glass Co., Ltd.) as a reinforcing glass fiber as a filler, and zinc stearate as an internal mold release agent. After 2.0 parts of SZ-2000 (trade name, manufactured by Sakai Chemical Industry Co., Ltd.) was charged and kneaded for 1 minute, the kneader was stopped, and 250 parts of the same granular natural stone as described above was charged. After kneading for 20 minutes, the same reinforcing glass fiber
The mixture was added and kneaded for another 2 minutes and 15 seconds to complete the kneading. The total time of kneading by rotating the kneader is 5 minutes 1
5 seconds. The kneaded material was taken out of the kneader and the kneading process was completed.
kg) to obtain a preformed BMC. The particle size distribution of Fujioka Mikage used was 6
4% by weight of particles having a particle size of not less than
16% by weight of particles having a particle size of less than 2 mm, 24% by weight of particles having a particle size of 4 mm or more and less than 5 mm, 28% by weight of particles having a particle size of 3 mm or more and less than 4 mm, and 2% by weight.
20% by weight of particles having a particle size of not less than 3 mm and 1 m
7% by weight of particles having a particle size of not less than 2 mm
The particles having a particle size of less than m were 1% by weight. The kneader
The rotation speed was set to 29 to 38 rpm using an MS open type kneader; 100 L (trade name, manufactured by Moriyama Corporation).

Next, using a large-sized hydraulic press of 2500 tons, the obtained BMC was charged into a mold having dimensions of 760 mm × 3070 mm set at 135/130 ° C. using a BMC charging machine. The charge pattern of the BMC was such that seven BMCs were arranged in a row in the center along the long side of the mold, and arranged so that one side of the BMC and one side of the mold were parallel. Thereafter, press molding was performed at a pressure of 80 kgf / cm ² for 420 seconds to obtain a plate-like molded product having a thickness of about 13.5 mm, and the molding process was completed.

This molding step was performed twice to obtain two plate-like molded products. The surface of the two plate-like molded products obtained by the molding process was polished by about 1.5 mm using an automatic polishing machine AP-8 (trade name, manufactured by Gifu Seisakusho Co., Ltd.) which is a wet-type surface polishing device for natural stones. A polishing step was performed to obtain a plate-shaped molded product having a polished surface. Thereafter, two plate-shaped molded products whose surfaces were polished were cut with a wet diamond cutter to produce a long-sided one having a length of 3000 mm and a long-sided one having a length of 1000 mm. Next, a plate-shaped molded product having a long side dimension of 3000 mm and a surface-polished plate-shaped product having a long dimension of 1000 mm were arranged side by side in the longitudinal direction. On the bonding surface,
A cyano bond PX-300 (trade name, manufactured by Taoka Chemical Industry Co., Ltd.) is used as an adhesive and applied by a tube, and two plate-like molded products are pressed and bonded at the bonding surface and left at 28 ° C. for 10 minutes to bond. In this way, a plate-like molded product having a long dimension of 4000 mm was produced. The surface of the bonded plate-like molded product was adjusted to about 0.1 by using a wet stone polishing machine for natural stone.
A large artificial stone plate was obtained by performing surface polishing after polishing by mm. The obtained large artificial slab was evaluated by the method described below. The results are shown in Table 1.

[0083]Evaluation method  (1) Sensory test for design and high-grade appearance
Based on polished natural granite and marble
Whether it is excellent in design and whether it has a sense of quality
Was visually observed and evaluated by 21 persons (odd number persons).
Based on the results, the number of people who
And the number of people who were evaluated as having a high-class feeling.

In the organoleptic test of the design and luxury of the obtained large artificial stone plate, more than half of the people who evaluated natural granite and marble were evaluated as “excellent in design” based on polished natural granite and marble. In the case where the large artificial stone slab is considered to be excellent in designability, if more than half of the evaluated people are evaluated as `` having a high class feeling '', it is said that the large artificial stone slab has a high class feeling Conceivable.

Comparative Example 1 In Example 1, cyanobond PX-3 was used as the adhesive.
00 (trade name, manufactured by Taoka Chemical Industry Co., Ltd.) using a tube, and two plate-like molded products were pressed against each other with an adhesive surface.
A large artificial stone plate was obtained in the same manner except that the surface was not polished for the bonded plate-like molded product. Table 1 shows the results of the evaluation of the obtained large artificial stone slab by the method shown in Example 1.

Comparative Example 2 A large artificial stone plate was prepared in the same manner as in Comparative Example 1, except that the surface of the bonded plate-like molded product was polished only at the portion of the bonded surface by hand using a No. 800 sandpaper. Obtained.
Table 1 shows the results of the evaluation of the obtained large artificial stone slab by the method shown in Example 1.

[0087]

[Table 1]

As is clear from Table 1, the large artificial stone slab obtained in Example 1 had uniform basic performance over the entire surface, was excellent in designability, and had a high-grade feel. In addition, the bonding surfaces of the two plate-like molded products were less noticeable. On the other hand, the large artificial stone slabs obtained in Comparative Examples 1 and 2 do not have uniform basic performance over the entire surface as compared with the large artificial stone slabs obtained in Example 1; Was inferior. Further, the adhesive surfaces of the two plate-like molded products were easily conspicuous.

[0089]

The method for manufacturing a large artificial stone slab of the present invention, which has the above-described structure, is capable of eliminating defects in the bonding surface and producing a large artificial stone slab having an excellent design and a sense of quality. It is.

 ──────────────────────────────────────────────────の Continuing on the front page (72) Koji Takahata 5-8, Nishiobari-cho, Suita-shi, Osaka Nippon Shokubai Co., Ltd. F-term (reference) 4F213 AA36 AA41 AA43 AB11 AC01 AC04 AD04 AD05 AF09 AF10 AF11 AF12 AH48 AH49 WA04 WA15 WA43 WA53 WA56 WB01 WC01 WF21

Claims (2)

[Claims] 1. A kneading step of introducing a matrix material containing a matrix resin and a filler and granular natural stone into a kneading machine to obtain a composition for an artificial slab, and forming the composition for an artificial slab in a mold. Forming a large artificial stone plate having a size larger than the mold, the molding process comprising: Glue things with adhesive,
A method for producing a large artificial slab, wherein the surface is polished thereafter. 2. A large artificial stone slab manufactured by the method for manufacturing a large artificial stone slab according to claim 1.