Method for producing artificial marble having stripe patterns

Details Method for producing artificial marble having stripe patterns Method for producing artificial marble having stripe patterns

1999-11-24

2001-10-23

Silbaugh, Jan H. (Department: 1732)

Plastic and nonmetallic article shaping or treating: processes

Random variegated coloring during molding

C264S245000

Reexamination Certificate

active

06306321

ABSTRACT:

BACKGROUND OF THE INVENTION
TECHNICAL FIELD
The present invention relates to a method for producing artificial marble having a stripe pattern.
BACKGROUND ART
Conventionally, artificial marble used in counters of wash stands, table tops and the like has been produced by curing a liquid resin. As a method for producing such artificial marble carrying patterns on the surface, Japanese Patent Application Publication (JP-B) No. 59-1568 and Japanese Patent Application Laid-Open (JP-A) No. 1-317723 discloses a method in which a synthetic resin material of different color is mixed by injecting a liquid resin into a molding cell.
However, according to these conventional methods, there are problems that reproducibility of pattern manifestation is deficient, and production yield for obtaining an excellent product is low. Further, when the product is used as artificial marble, the surface thereof is often shaved and therefore keeping of the surface pattern is required in this process. However, in many cases, the pattern disappears or changes significantly by shaving. Moreover, when an extraneous material is used for manifestation of a pattern, a difference in curing speed tends to occur and a difference in physical properties between materials tends to occur, consequently, the mechanical properties of the artificial marble may sometimes decrease as compared with that having no pattern.
The present inventors have suggested, as a method for solving the above-described problems, a method in which liquid resins having different colors are laminated in a molding cell, and comb-like tools are allowed to move in the molding cell before the resins are cured to produce artificial marble in U.S. Pat. No. 5,837,175. According to this method, a stripe pattern having a clear appearance can be simply formed and control of this pattern is easy, and further, a pattern can be formed continuously also along with thickness direction.
However, visual feeling is flat and a simple pattern is liable to be formed according to this method, therefore, the resulting artificial marble is not fully satisfactory from the standpoint of appearance as compared with natural woody materials and other natural marble. Particularly, there is room for improvement in view of the delicate hue, depth, texture and a luxury feeling owned by natural substances such as natural wood, natural stone and the like.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a method for producing artificial marble in which a radial cut moire pattern having a delicate hue of wood and natural appearance, or a stripe pattern having a natural marble-like appearance excellent in texture and deep feeling can be formed and control of this pattern is easy.
Another object of the present invention is to provide a method for producing artificial marble which has a stripe pattern which can be formed continuously along the thickness direction and does not disappear even if surface is shaved.
Namely, the present invention provides a method for producing artificial marble having a stripe pattern by curing liquid resins in a molding cell, comprising injecting a liquid resin in which a coloring agent is dispersed non-uniformly into a molding cell, laminating one or more liquid resins having different colors to form one or more layers on the liquid resin in which a coloring agent is dispersed non-uniformly, and moving a comb-like tool through the laminated liquid resins while allowing the teeth to contact the bottom surface of the molding cell.


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