JP3251353B2 - Cylindrical high-density artificial stone and its production method - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a cylindrical high-density artificial stone and a method for producing the same. More specifically, the present invention relates to a high-density artificial stone having a marble-like excellent texture and a method for producing the same, and provides an artificial stone useful as a stone pillar or the like.

[0002]

2. Description of the Related Art It has been known that a natural stone is crushed to an appropriate size, mixed with an inorganic substance such as calcium carbonate and a resin, and then hardened into an artificial stone. That is, for example, see JP-A-61-10
No. 1443 discloses a method of obtaining a mass of the obtained artificial stone that can withstand the cutting process. Raw stone powder, resin, and the like are mixed under reduced pressure, and the mixture is poured into a mold. And taking out and subjecting to cutting.

Further, Japanese Patent Publication No. 53-24447 discloses that when artificial stone is manufactured by using natural stone powder and synthetic resin, raw materials are used at a predetermined mixing ratio, The necessity of applying sufficient pressure after being put into the container is described. Therefore, as pointed out in these known examples, a problem in artificial stone obtained by such a method is that since molding is performed using a mold, air bubbles remain inside the molded body. In addition, fluidity for pouring the resin and the stone into the mold must be ensured.

Therefore, for example, Japanese Patent Publication No. 53-24447.
In the publication, fluidization is achieved by increasing the amount of the resin component, and the generation of bubbles can be prevented by ensuring fluidization. However, on the other hand, increasing the resin component to prevent the generation of air bubbles and to ensure the fluidity for feeding into the mold is completed even if it is useful for ensuring the fluidity and preventing the generation of air bubbles. The nature of the artificial stone has an adverse effect.

[0005] In other words, the use of a large amount of the resin component leads to the conversion of the product into a resin, and the obtained product merely has powder particles of natural stone in the resin. It has become close to. Therefore, although it is called artificial stone, what is obtained is a resin product that looks like stone. In addition, when using a mold, pressurizing the mold in a sealed state means that the generated foam is only crushed, it cannot be essentially escaped, part of it remains on the surface or inside of the product and the surface It loses aesthetics and degrades its physical properties.

[0006] As described above, the conventional artificial stone has a serious problem in its composition, and there is a limitation in forming itself by using a mold. For this reason, the fact is that artificial stones of any shape having excellent texture have not yet been realized. Therefore, to resolve the disadvantages of such conventional artificial stone,
When using natural stone or other powder as a material, the resulting product has a high density and physical properties similar to that of natural stone. Vigorous investigations have been made on the improved composition of artificial stones and their production methods that enable them to be obtained and to have an arbitrary shape by securing physical properties.

[0007] The present invention has been made in view of the above-mentioned circumstances, and provides a texture of natural stone, and uses less expensive pure stone, recovered fine powder, and other inorganic raw materials, and is used for building. It is an object of the present invention to provide a new artificial stone, particularly a cylindrical high-density artificial stone, which can be easily used for a cylindrical shape useful as a stone pillar or the like of an object, and a method for producing the same.

[0008]

DISCLOSURE OF THE INVENTION The present invention has been made to solve the above problems, and comprises an inorganic fine particle component having a size of 10 to 70 mesh and an inorganic fine particle component having a size of 100 mesh or more. The weight ratio is 0.5: 1 to 5: 1,
A cylindrical height characterized in that the sum is 85% by weight or more of the product and the resin component has a mixed composition of 15% by weight or less, is molded and solidified into a cylindrical shape, and has a polished surface. The present invention also provides a high-density artificial stone, characterized in that the artificial stone is solidified and integrated with a cylindrical concrete molded product.

Further, according to the present invention, the weight ratio of the inorganic fine particle component having a size of 10 to 70 mesh to the inorganic fine particle component having a size of 100 mesh or more is 0.5: 1 to 5: 1, and the sum of the components is 85% by weight or more and the resin component is 15
A method for producing a high-density cylindrical artificial stone, which comprises introducing a mixed composition of not more than 10% by weight into a rotating cylindrical mold, centrifugally molding and solidifying the mixture, and then polishing the surface. The present invention also provides a method for producing a cylindrical high-density artificial stone, characterized in that concrete is charged into the inside of a molded body, centrifugally molded and solidified integrally.

Therefore, the present invention will be described in more detail. First, the raw materials constituting the artificial stone of the present invention are roughly classified into three components. One is a fine-grained component having a size of 10 to 70 mesh as a main component, and an appropriate fine-grained component selected from natural stone, ceramics, glass, metal and the like is used. Some of these small pieces may be mixed in them.

[0011] Further, 1
Fine particles having a size of 00 mesh or more are also used, and examples of the fine particles include various natural or artificial fine particles. Calcium carbonate, aluminum oxide and the like are easy-to-obtain fine-grained components. The third component is a resin component. The resin component can be selected from a wide range of thermosetting ones.

For example, acrylic resin, unsaturated polyester resin and the like are exemplified. Fine-grained components such as natural stones function as major factors in the appearance and physical properties of the resulting artificial stone. In particular, by exposing a part thereof, it becomes a main factor of the appearance color and pattern in combination with other components. The fine-grained component is considerably finer than the 100-grain level compared to the fine-grained component. The fine-grained component is positioned so as to penetrate between the individual grains of the fine-grained component and fill the space between the grains. It contributes to obtaining properties such as hardness and flexibility. The fine particle component and the fine particle component are in a weight ratio of 0.5: 1.
５5: 1 is preferred.

In addition, the resin component is a component for forming fine particles such as natural stone, which is a component forming the above-mentioned skeleton, and fine particles.
It has a function of wrapping these and contributing to the whole and giving elasticity or tensile strength to the product when the artificial stone is completed. In the present invention, the composition ratio of these components is important. Particularly important is the composition ratio between the resin component and other components. The high density means that the fine and fine components contained in the product are present at a high density, and the degree is, for example, higher than that of the conventional artificial stone having a density of 2 g / cm ³ or more. Is out of range.

That is, as the composition ratio of fine-grained components such as natural stones as a skeleton component in a product increases, the composition becomes closer to natural stones. However, when the composition ratio is too large, the composition does not solidify and cannot be used as a product. In addition, the physical properties of the resulting product are poor and cannot be used in normal usage. Further, in addition to inconveniences such as not hardening even when a large amount of fine particles are used, the resulting material is dull and hard to be called stone.

Accordingly, the proportion of the fine-grained component and the fine-grained component used is limited. That is, the weight ratio must be 85% or more, and preferably 90% or more. If it exceeds 98%, the product becomes brittle, and only those which are difficult to use can be obtained. On the other hand, if it is less than 85%, the product is too soft to obtain stone-like properties, and the range of use is similar to that of the resin plate.

This means that the components other than the fine and fine components such as natural stones, that is, the resin component, must not be present in the product at most in a weight ratio of more than 15%. If the resin component exceeds about 15%, the product becomes plastic, and the artificial stone is no longer just an apparent name. Also, reducing the resin component may increase the tendency of the product to be stone, but the product becomes brittle and unsuitable for use. In reality, it has conventionally been difficult to reduce the content of components such as resin to 10% or less.

The fine particle component has a size of 10 to 70 mesh as described above, but it is preferable to use only the same size component except for special cases. For example, it is conceivable to change the size of fine grains depending on the presence or absence of color when it is desired to add a color to the top or bottom using one with and without a color. The use of large quantities with differences should not be used as it will degrade the strength of the product.

As described above, the size of the fine component particles must be sufficient to allow the fine component particles to enter between the fine component particles. Therefore, those having a size close to the size of the particles of the fine component are not preferred, and those having a size of about 150 to 250 mesh are preferred. What is important in the high-density artificial stone of the present invention is that, except for special cases, it is desirable that these material compositions are uniformly dispersed in any part of the product.

The surface constituting the outside of the product must be polished. That is, it is preferable that at least a part of the surface has the fine grain component exposed.
Polishing is a practical and convenient method for exposing the surface of the dense texture of high-density artificial stone. It should be noted that a part of the surface of the product may be polished to expose fine-grained components, and a difference between the surface and the other part of the same surface may be used as a pattern.

In the case of obtaining artificial stones, it is important to determine what natural stones are targeted. Marble is a popular target because it is difficult to obtain natural marble and its color and luster are beautiful. In this case, the color and luster are important themes that determine the value of marble. In natural marble, there are many types of colors, from completely black to white or red, and the degree is different even for the same color.

Therefore, when giving a color corresponding to these,
For example, in order to obtain a black product, it is only necessary to use a black material such as natural stone or the like, but to obtain a product with an intermediate color,
Difficulty in reproducibility. Providing the unique luster of marble, even with the addition of color, required considerable effort and was sometimes difficult. In particular, it was difficult to give gloss when a color was given using a dye or pigment.

On the other hand, in the present invention, in order to obtain a glossy material such as marble, fine particles obtained by pulverizing quartz-based natural stone are used as the fine particle components. Fine particles obtained by grinding quartz-based natural stone have a unique smooth surface because the raw material is quartz-based. They are often colorless and transparent. They are not very strong when they have colors, and they often have some transparency even when they are not transparent.

When the raw materials selected in this way are used, the color of the obtained product is mainly the color of the resin. Moreover, the color can be seen to have a luster due to the presence of the fine quartz-based component. For example, when a polyester-based unsaturated resin is used as the resin, the color of the resin is generally white with a slightly yellow tint, and the resulting product is glossy milky white, which is very similar to natural milky white marble. A product with a different color tone can be obtained.

When a color is added to a product by adding a pigment or the like to a resin component, a product having a uniform color and a unique color tone can be obtained by using a fine-grained component as a quartz-based component. When adding color to a product, the fine-grained component obtained by crushing quartz-based natural stone is used as it is without any processing for color, and in addition to this, a granular component of approximately the same size as the fine-grained component is used as a color component. Can be used in combination with a colored material to give a color to the product.

At this time, if the mixing ratio of the quartz-based fine-grained component which is not processed with respect to the color and the colored component is kept constant, a product having a constant color tone can be obtained. In this case, the reproducibility of the color is much easier than the conventional method of coloring the resin side or using a pigment or the like, there is no discoloration, and the gloss is accurately reproduced. An excellent product is obtained as compared with the conventional coloring method.

Even when a special color is given by using a plurality of kinds of colored fine-grained components, the color adjustment by adding a quartz-based fine-grained component that has not been processed for the color has an extremely excellent effect. Things. Naturally seeking colored fine-grained ingredients is a good method, but the amount is limited,
Colors are limited.

Therefore, it is effective to apply a glaze for coloring ceramics or the like to a natural powder and bake it to obtain a powder of a desired color and use it as a fine component. By using this method, not only can the color of the colored body be assured, but also the color can be widely selected. Granular powder of quartz-based natural stone used as the fine-grained component is used as the fine powder, and glaze is applied and baked on it. There is no concern about the reproducibility of the color, and the reproduced color is not only the color itself, but also the gloss and the color tone, and is completely reproduced.

The high-density artificial stone of the present invention, which also has such excellent color tone characteristics, has a cylindrical shape so that it can be applied as a stone pillar or the like in its shape. Various types of cylinders and prisms are included. The molding method for this is also variously selected. For example, centrifugal molding in the case of a cylindrical shape, cast molding, compression molding and the like are considered.

In any case, what is important as the production method of the present invention is that the mold used is not a closed mold. That is, the open portion must clearly be part of the total surface area. For example, when obtaining a rectangular tubular article, it is preferable to use a mold in which the portion forming the edge of the plate inside the mold is open, with the open side higher than the other side.

The opening may sometimes be semi-opened at the narrow side, in addition to the upper side, that is, it may be meshed so that, for example, the fine-grained component hardly flows out. The size of the part to be opened is several percent of the total external area of the internal volume of the mold.
The following may be sufficient. Further, when a fluid state in which a resin component, a fine-grained component, and a fine-grained component are uniformly mixed is injected into such a mold, it is necessary to reduce the internal volume of the mold after the injection.

For example, when the inside of the mold is flat,
Close the flat plate portion of the mold to reduce its thickness. Due to the reduction of the internal volume, the resin component comes out from the inside, gathers at the open part of the mold, and overflows from the open part of the mold. Alternatively, after the injection, the resin component on the upper side flows out by pushing up the bottom part to reduce the internal volume.

That is, since the fine-grained component and the fine-grained component have an apparently higher specific gravity than the resin component, they begin to sink below when injected into the mold. This subsidence occurs quickly because of the large difference in specific gravity. Therefore, when the internal volume is reduced, only the light resin component is pushed outward and moves,
Gather to open areas. Therefore, if the internal volume is previously set to a predetermined value and then the predetermined volume is reduced, a controlled amount of the resin component can be taken out. Therefore, the resin component participating in the solidification is smaller than the amount of the resin component at the time of the injection, and the ratio of the amount of the resin contained in the product can be made smaller than that at the time of the injection.

In the case of cylindrical artificial stone, centrifugal molding as a well-known method can be employed. In this method, the composition of the present invention as described above is charged inside a hollow cylindrical mold that is rotated by a roller or the like, and a hollow cylindrical composition layer is formed on the inner surface of the mold. Is carried out by solidification. The number of rotations may be appropriately selected. This centrifugal molding produces a dense, artificial cylindrical stone with a dense tissue.

In this case, after the composition is solidified and cured by centrifugal molding, or before solidification, concrete may be introduced and integrated. This allows
The application as a structural material such as a stone pillar is expected to further expand. Hereinafter, examples will be described. Of course, the present invention is not limited by the following embodiments.

[0035]

EXAMPLE 1 9 wt% of a quartz natural stone having a particle size of 15 to 30 mesh and calcium carbonate having a mesh size of 230 so as to be 90 wt% of the total weight of the composition at an important ratio of 2: 1. %
Was uniformly mixed with the polymethyl methacrylic resin and 1% by weight of a curing agent to obtain a mortar-like composition.

This composition was charged into a hollow rotary mold having a diameter of 300 mm to form a hollow cylindrical composition layer having a thickness of about 40 mm. This was cured in a curing room at 80 ° C. for 5 hours or more, and left for about 10 hours. After demolding, the surface was polished. The resulting cylindrical artificial stone has a perfect marble-like milky white color and luster, with no air bubbles inside or on the surface,
The composition appeared on each surface was uniform.

The artificial stone thus obtained had a specific gravity of 2.20, a tensile strength of 120 kg / cm ² , a compressive strength of 600 kg / cm ² and a bending strength of 640 kg / cm ² , showing a state close to that of natural marble. Quartz-based fine grains were found on the polished surface. When the obtained product was used as a building pillar,
A beautiful marble pillar was obtained. Example 2 In Example 1, the thickness of the composition layer was set to 10 mm, concrete was put inside, and the composition layer was formed to have a thickness of about 30 mm.

In the same manner as in Example 1, an artificial stone useful as a stone pillar was obtained. Tensile strength 130 kg / cm ² , compressive strength 605 kg / cm ² , bending strength 660 kg / cm ²
And had an excellent marble-like surface.

[0039]

The present invention provides a high-density artificial stone containing a granular material such as a high-density natural stone, which has not been obtained before, and a method for producing the same.
The properties are close to those of natural stone, and a uniform product that is difficult to obtain from natural products can be obtained. Moreover, such excellent products can be manufactured without using specially expensive equipment.

In particular, the high-density artificial stone of the present invention is suitable for obtaining a marble-like stone, and can be used in the same manner as natural stone. The product has the same color tone as that polished from a natural stone, and particularly has a luster. The product can be integrated with concrete, and can be used as a stone pillar or the like in a wider variety of uses than natural products.

Conventionally, artificial marble, which was merely an apparent one, can be provided that is substantially inferior to natural ones, is easier to use, and has artificial advantages.

──────────────────────────────────────────────────の Continued on the front page (51) Int.Cl. ⁷ identification code FI C04B 20:00) C04B 20:00) B B29K 103: 04 B29K 103: 04 (58) Fields surveyed (Int.Cl. ⁷ , (DB name) C04B 26/00-26/32 C04B 20/00-20/12 B28B 1/20

Claims (6)

(57) [Claims] The weight ratio of the inorganic fine particle component having a size of 10 to 70 mesh to the inorganic fine particle component having a size of 100 mesh or more is 0.5: 1 to 5: 1, and the sum is 85% by weight of the product.
A cylindrical high-density artificial stone characterized by the above, wherein the resin component has a mixed composition of 15% by weight or less, is molded and solidified into a cylindrical shape, and has a polished surface. 2. A high-density cylindrical artificial stone, wherein the artificial stone according to claim 1 is solidified and integrated with a cylindrical concrete molded body. 3. The method according to claim 1, which is formed and solidified into a cylindrical shape.
Or 2 cylindrical high density artificial stone. 4. The weight ratio of the inorganic fine particle component having a size of 10 to 70 mesh to the inorganic fine particle component having a size of 100 mesh or more is 0.5: 1 to 5: 1, and the sum is 85% by weight of the product.
A cylinder characterized in that the mixed composition having a resin component of 15% by weight or less is put into a rotating cylindrical mold, centrifugally molded, solidified, and then surface-polished. Manufacturing method of high-density artificial stone. 5. The method for producing an artificial stone according to claim 4,
A method for producing a cylindrical high-density artificial stone, comprising: after solidifying and curing by centrifugal molding, putting concrete inside the molded body, centrifugally molding and solidifying and integrating. 6. The method for producing an artificial stone according to claim 4,
A method for producing a cylindrical high-density artificial stone, characterized in that, during centrifugal molding, concrete is put into the inside of the composition before the composition is solidified, molded and solidified and integrated.