JP-7854789-B2 - Artificial marble and its manufacturing method

JP7854789B2JP 7854789 B2JP7854789 B2JP 7854789B2JP-7854789-B2

Inventors

澤野陽介
平木誠
塩見明
可知直人
柴田浩治

Assignees

株式会社LIXIL

Dates

Publication Date: 20260507
Application Date: 20210915

Claims (9)

Design layer and, A substrate layer containing multiple balloons, An intermediate layer located between the design layer and the base material layer, which does not contain balloons but contains glass fibers, comprising: The thickness of the aforementioned intermediate layer is 0.1 mm or more and 1.1 mm or less. Artificial marble, wherein the design layer, the base layer, and the intermediate layer are each composed of an unsaturated polyester resin .
The artificial marble according to claim 1, wherein the balloon includes a resin balloon.
The artificial marble according to claim 1 or 2, wherein the glass fibers function as a sagging prevention material.
The aforementioned glass fibers function as a shrinkage inhibitor, as described in any one of claims 1 to 3, for the artificial marble.
The artificial marble according to any one of claims 1 to 4 , wherein the thickness of the intermediate layer is 0.3 mm or more.
The artificial marble according to any one of claims 1 to 5 , wherein the thickness of the intermediate layer is 0.5 mm or more.
The artificial marble according to any one of claims 1 to 6 , wherein the thermal conductivity of the base material layer is 1 W/m·K or less.
The artificial marble according to any one of claims 1 to 7 , wherein the density of the base material layer is 1.5 g/ cm³ or less.
A method for manufacturing artificial marble comprising a design layer, a base layer containing a plurality of balloons, and an intermediate layer located between the design layer and the base layer, which does not contain balloons but contains glass fibers, The aforementioned manufacturing method is A first material for forming the design layer is applied to the surface of the mold. A second material for forming the intermediate layer, wherein the second material is applied on the first material. A third material for forming the base layer, wherein the third material including the plurality of balloons is poured into the mold. The thickness of the aforementioned intermediate layer is 0.1 mm or more and 1.1 mm or less. A manufacturing method wherein the design layer, the base material layer, and the intermediate layer are each composed of an unsaturated polyester resin .

Description

The technology disclosed herein relates to artificial marble and methods for producing the same. Patent Document 1 discloses a technique for reducing the weight of artificial marble by incorporating glass micro-hollow spheres into a resin composition. Japanese Patent Publication No. 2006-62904 A cross-sectional view showing the composition of artificial marble.Enlarged view of Part II in Figure 1.A schematic flowchart illustrating the manufacturing method of artificial marble.A table showing the results of performance evaluation tests.A table showing the results of the thick-film coating performance test. (Composition of artificial marble: Figures 1 and 2) The structure of the artificial marble 10 will be described with reference to Figures 1 and 2. The artificial marble 10 is used in residential equipment such as washbasins, kitchen counters, and bathtubs. As shown in Figure 1, the artificial marble 10 comprises a design layer 12, an intermediate layer 14, and a base layer 16. In this embodiment, the artificial marble 10 is characterized by comprising an intermediate layer 14 having a different composition from the design layer 12 and the base layer 16. In this embodiment, the thickness of the design layer 12 is, for example, 0.30 to 0.60 mm. The design layer 12 has a design surface 12a located on the uppermost surface of the artificial marble 10. Therefore, when the artificial marble 10 is used in residential equipment, the user will see the design surface 12a. The design layer 12 is composed of a resin material. In this embodiment, the resin material is a thermosetting resin, specifically an unsaturated polyester resin. In a modified example, the resin material may be other materials such as vinyl ester resin, epoxy resin, or acrylic resin. In another modified example, the resin material may be a resin material different from the thermosetting resin (e.g., urethane resin, acrylic urethane resin, etc.). In this embodiment, the thickness of the base layer 16 is, for example, 10 mm or more. The upper limit of the thickness of the base layer 16 is not particularly limited. Considering strength and moldability, the upper limit of the thickness of the base layer 16 is preferably 30 mm or less. If moldability is more important, 25 mm or less, and even more preferably 20 mm or less, is preferable. The base layer 16 is composed of a resin material. In this embodiment, the resin material is a thermosetting resin, specifically an unsaturated polyester resin. In a modified example, the resin material may be other materials such as vinyl ester resin, epoxy resin, or acrylic resin. In another modified example, the resin material may be a resin material different from the thermosetting resin (e.g., urethane resin). As shown in Figure 2, the base layer 16 includes a plurality of balloons 18. The balloons 18 are spherical hollow bodies. The balloons 18 are composed of an organic material. In this embodiment, the balloons 18 are resin balloons. In a modified example, the balloons 18 may be composed of an inorganic material such as a ceramic balloon. When the base layer 16 contains balloons 18, the density of the base layer 16 is lower compared to when the base layer 16 does not contain balloons 18, making it possible to realize a lightweight artificial marble 10. The density of the base layer 16 can be adjusted by the mixing ratio of balloons 18. In order to achieve weight reduction, the density of the base layer 16 is preferably 1.5 g/ cm³ or less, and in this embodiment it is 0.5 g/ cm³ . In a modified example, the density of the base layer 16 may be greater than 1.5 g/ cm³ , for example, 1.7 g/ cm³ . The balloon 18 has a gas layer inside. This reduces the thermal conductivity of the base layer 16, increasing the thermal insulation of the artificial marble 10. High thermal insulation of the artificial marble 10 helps prevent users from feeling that the artificial marble 10 is cold when they come into contact with it, for example, in winter. The thermal conductivity of the base layer 16 can be adjusted by the mixing ratio of the balloon 18. To achieve thermal insulation that can prevent user discomfort, the thermal conductivity of the base layer 16 is preferably 1 W/m·K or less, and in this embodiment, it is 0.11 W/m·K. In a modified example, the thermal conductivity of the base layer 16 may be greater than 1 W/m·K, for example, 1.1 W/m·K. The intermediate layer 14 is located between the design layer 12 and the base layer 16. The intermediate layer 14 is composed of a resin material. In this embodiment, the resin material is a thermosetting resin, specifically an unsaturated polyester resin. In a modified example, the resin material may be other materials such as vinyl ester resin, epoxy resin, or acrylic resin. In another modified example, the resin material may be a resin material different from the thermosetting resin (e.g., urethane resin). As shown in Figure 2, the intermediate layer 14 does not contain balloons 18