KR100882087B1 - A Preparing Method of Artificial Marble With Steal Making Slag And An Artificial Marble Prepared Thereby - Google Patents

Abstract

The present invention relates to a method for manufacturing artificial marble using steelmaking slag and to artificial marble prepared accordingly, wherein the mixed slag is composed of 75 to 85% by weight of steelmaking slag having a particle size of 1.18 to 3.35 mm and 15 to 25% by weight of fine grained steel slag having a particle diameter of less than 1.18mm. After mixing 65 to 70% by weight of thermosetting resin and 30 to 35% by weight of thermosetting resin, hot-molding method for manufacturing artificial marble, 95 to 80% by weight of steel slag having a particle size of 1.18 to 3.35 mm, and fine steel slag having a particle diameter of less than 1.18 mm 15 A mixture of 65 to 70% by weight of the mixed slag and 25 to 35% by weight of the thermosetting resin was charged into a mold and flattened, and then the decorative chip having a particle size of 1 to 10 mm as a cosmetic layer thereon before being completely cured. There is provided a method of preparing a multilayer artificial marble having a cosmetic layer by charging a mixture of 60 to 80% by weight and 20 to 40% by weight of a thermosetting resin, and hot pressing to provide a synthetic marble prepared accordingly. The artificial marble of the present invention is not only beautiful in appearance but also excellent in strength.

Steel slag, artificial marble, duplex artificial marble

Description

Manufacture method of artificial marble using steelmaking slag and artificial marble prepared according to the present invention {A Preparing Method of Artificial Marble With Steal Making Slag And An Artificial Marble Prepared Thereby}             

1A and 1B are photographs showing a side cross-sectional view and a plan view of the artificial marble of the present invention prepared by the method of Example 3. FIG.

The present invention relates to a method of manufacturing artificial marble using steelmaking slag and artificial marble prepared accordingly, and more particularly, to a method of manufacturing a multilayer artificial marble composed of a base layer and a surface cosmetic layer using steelmaking slag, and a multilayer manufacturing manufactured accordingly. It's about marble.

Commercially available artificial marble is a composite plate of an inorganic filler and a polymer material.                         

Japanese Patent Application Laid-Open No. 5-239329 and Korean Patent Application No. 2000-7011957 disclose an artificial marble using aluminum hydroxide, silica, molten silica, and glass powder as inorganic fillers.

In addition, Korean Patent Application No. 1998-63497 discloses calcium carbonate, talc, clay, silica, alumina, quartz, calcium silicate, aluminum hydroxide, magnesium hydroxide, calcium hydroxide and the like having an average particle of 5 to 50 μm as an inorganic filler. Korean Patent Application Nos. 1999-7011142, 2000-60914, Japanese Patent Laid-Open No. 5-330884, Japanese Patent Laid-Open No. 5-339460, Japanese Patent Laid-Open 53-104621 and Japanese Patent Laid-Open 61-178458 as inorganic fillers such as aluminum hydroxide, magnesium hydroxide, calcium hydroxide and sulfuric acid. Barium, calcium carbonate, silica, carbonate, borosilicate glass powder, glass powder, glass beads, glass fibers, glass fiber powder, calcium carbonate and the like are disclosed.

As the type of inorganic filler used in the prior art, similar powdery materials have been used. As such, when the powder is used as the inorganic filler, the filling density of the powder itself is low and the voids are increased, thereby increasing the amount of expensive polymer materials required to bind the inorganic filler between these voids, thereby increasing the manufacturing cost of the product.

On the other hand, steel slag is generated in large quantities as a by-product when iron production in the steel mill, and contains a large amount of valuable components as shown in Table 1.                         

[Table 1] Chemical composition (wt%) of various steel slag

CaO SiO2 T-Fe Al2O3 MgO MnO P2O5 converter 40.80 12.61 22.81 2.57 5.96 4.05 1.70 Dein 51.6 20.0 2.9 3.4 7.2 Deregulation 20.2 48.5 4.5 5.1 3.2 stainless 37.2 15.0 3.9 19.8 12.1 Oxidizer 33.85 16.79 20.1 11.61 2.68 5.84 0.38 Furnace Reduction Machine 51.82 4.85 0.1 35.15 6.50 0.1 0.01

Each steelmaking slag includes other balances such as iron oxide, calcium hydroxide and calcium carbonate.

In particular, steelmaking slag has high hardness, high strength and good abrasion resistance and is used as a road anti-slip material. However, if steel slag is used, the color of the product becomes black, so that various colors of products cannot be produced.

Accordingly, an object of the present invention is to provide a method of manufacturing artificial marble of high density and high strength using steelmaking slag and artificial marble manufactured accordingly.

Another object of the present invention is to provide a multi-layer artificial marble manufacturing method having a beautiful appearance having a cosmetic layer and the artificial marble prepared accordingly.

According to one aspect of the invention,                     

70 to 85% by weight of steel slag with a particle size of 1.18-3.35 mm and 35 to 45 parts by weight of thermosetting resin per 100 parts by weight of the mixed slag of fine steelmaking slag having a particle diameter of less than 1.18 mm are mixed, followed by hot pressing. A method of making marble is provided.

According to another aspect of the present invention,

70 to 85% by weight of steelmaking slag with a particle size of 1.18 to 3.35 mm and 35 to 45 parts by weight of thermosetting resin per 100 parts by weight of the mixed slag of fine steelmaking slag having a particle diameter of less than 1.18 mm are charged and flattened. Thereafter, a mixture of 60 to 80% by weight of a decorative chip having a particle size of 1 to 10 mm and 20 to 40% by weight of a thermosetting resin was charged into the cosmetic layer before it was completely cured, followed by hot pressing to prepare a multilayer artificial marble having a cosmetic layer. A method is provided.

According to another aspect of the present invention,

Artificial marble prepared by the method of the present invention is provided.

EMBODIMENT OF THE INVENTION Hereinafter, this invention is demonstrated in detail.

The present invention relates to a method for producing an inexpensive, high strength and high density artificial marble using steelmaking slag which is a by-product generated in a steel mill, and to an artificial marble manufactured accordingly.

In addition, the artificial marble manufactured by using steelmaking slag is black color, so that the multi-layer artificial marble manufacturing method having a multi-colored cosmetic layer on its surface to expand its application, and the multilayer artificial marble produced accordingly will be.

In the present invention, as a slag in the production of artificial marble, a mixed slag of granulated steel slag and finer steel slag is used as an inorganic filler.

As the granulated steel slag, a steel slag with a particle size of 1.18 to 3.35 mm and iron component removed is used. For example, an anti-slip slag having a particle size distribution that passes through a 3.35 mm sieve and does not pass through a 1.18 mm sieve may be used. Anti-skid steel slag is most preferred as a filler because it is uniform in particle size and contains little impurities such as iron granules.

To control the filling rate, fine steel slag with a particle size less than 1.18 mm is used together with the assembled steel slag. That is, the filling rate of the slag is increased by using the fine grained steel slag having a smaller particle size than the granulated steel slag.

70 to 85% by weight of the granulated steelmaking slag and 15 to 30% by weight of fine grained steel slag having a particle diameter of less than 1.18 mm are mixed. The granulated steel slag has a porosity of 46.2%, and as the addition amount of fine steelmaking slag is increased by up to 30% by weight, the porosity decreases by up to about 36%. However, even if the content of the fine steelmaking slag exceeds 30% by weight, the effect of reducing the porosity is no longer increased, and compared to the decrease in the porosity, it is not preferable because the amount of the polymer resin is increased due to the presence of a large amount of the fine slag. If the content of fine steelmaking slag is less than 15% by weight, the effect of reducing the porosity is insufficient.

After mixing the polymer resin in the mixed slag, hot pressing and curing to prepare artificial marble. Any kind of thermosetting resin may be used as the polymer resin, and examples thereof include unsaturated polyesters.

The thermosetting polymer resin is mixed in an amount of 35 to 45 parts by weight based on 100 parts by weight of the mixed slag. When the content of the thermosetting polymer resin is less than 35 parts by weight, the surface becomes rough during slag production. When the content of the thermosetting polymer resin is more than 45 parts by weight, the slag content is low and the appearance is not beautiful but the strength is low.

Steelmaking slag can be used converter slag, dephosphorous slag, de-silica slag, stainless slag, electro-oxidizer slag, electro-reduction group slag and mixtures thereof.

Hot press molding is generally performed according to the time required at a temperature of about 200 ° C. or less, and is performed under suitable conditions. Thereafter, curing is performed to prepare artificial marble. At this time, the shape of the artificial marble can be molded into any desired shape, for example, it can be produced in a plate or the like.

The produced slag artificial marble is a high-strength slag-polymer composite with a black color. The produced slag artificial marble can also be polished by polishing the surface, or it can be made of multilayer artificial marble with a makeup layer to impart various colors.

The multilayer artificial surrogate first mixes the mixed slag of the granulated steel slag and the fine steelmaking slag with the thermosetting polymer resin at the above-mentioned ratio, and forms a base layer using this mixture (hereinafter, referred to as a "base forming mixture"). The base-forming mixture is charged into a mold, flattened, charged with a cosmetic layer formulation on the base layer surface before the surface is completely cured (slightly cured), and hot press-molded to produce an integral multilayer artificial marble.

"Before fully hardened" or "slightly hardened" refers to the extent to which the cosmetic layer blend does not fall from the base layer and can be integrated.                     

The reason why the base compound is slightly cured before adding the cosmetic layer compound is to prevent the base layer compound and the cosmetic layer compound from spreading and mixing with each other and to form the base layer and the cosmetic layer integrally. To do this. The said hardening can be performed to the extent that it hardens slightly by blowing hot air on a surface.

The cosmetic layer blend refers to a mixture of the decorative chip and the polymer resin used for forming the cosmetic layer, and comprises a mixture of 60 to 80% by weight of the decorative chip having a particle size of 1 to 10 mm and 20 to 40% by weight of the thermosetting polymer resin. Thermosetting polymer resins are used in a little more than the amount that all the pores between decorative chips can be filled.

It is used only in the amount to fill the voids, because the surface is rough, in consideration of this, the thermosetting polymer resin is used in 20 to 40% by weight.

The particle size of the decorative chip is not particularly limited, but may be commercially available with a particle size of about 1 to 10 mm in consideration of aesthetics.

As a decorative chip, colored natural stones may be used by grinding or mixed with a calcium carbonate powder, a pigment of a desired color, and a thermosetting polymer resin, and then used to be ground to a desired size.

When the calcium carbonate powder, the pigment of the desired color and the thermosetting polymer resin are mixed and cured, and then used by grinding, the calcium carbonate powder is mixed with 30 to 70% and the thermosetting polymer resin 70 to 30% when the total weight is 100. In addition, the pigment can be used by mixing an appropriate amount depending on the purpose in the range of 0.1 to 5% by weight of the thermosetting polymer resin used. Calcium carbonate, thermosetting polymer resins and pigments are mixed in the above range in consideration of the color of the cosmetic layer to show the desired color, in some cases calcium carbonate powder may not be used to produce the desired color.

As the thermosetting polymer resin, the same resin as that used for preparing the base layer may be used. As the pigment, any pigment generally used may be used depending on the desired color.

White powder, which can express the color of the pigment well in the manufacture of decorative chips, can also be used. However, calcium carbonate is preferable because of the relatively low cost and excellent texture. Texture may vary depending on the particle size and distribution of chips for each color during grinding, and the particle size, distribution and relative amount of chips for each color when mixed with chips of different colors.

Hereinafter, the present invention will be described in more detail with reference to Examples.

<Example 1>                     

The filling rate change was measured while varying the mixing ratio of the granulated non-slip steelmaking slag having a particle size of 1.18-3.35 mm and the fine steelmaking slag having a particle size of less than 1.18 mm as follows. The fine steelmaking slag used slag separated through a 1.18mm sieve in the anti-slip agent manufacturing process.

The porosity of the assembled anti-slip slag was 46.2%. The porosity change was measured while adding 5, 10, 15, 20, 25 and 30% by weight of fine steelmaking slag. The slag was filled with slag in the container and then filled with water to measure the porosity in the slag as a content that can be filled with water. The porosity was reduced by about 10% when the slag was added up to 20% by weight, and the porosity was reduced by about 10% to 36.4% when the slag was added up to 25% by weight. Hardly happened.

<Example 2>

The granulated slag, particulate slag and the polyester resin were mixed in the amounts shown in Table 2, and then hot-formed and cured at 80 Kg / cm ² for 30 minutes at 80 ° C. in a pressure press to prepare a base plate in the form of a flat plate.

Porosity was measured as in Example 1 by mixing the granulated slag and the granular slag, evaluated by the flatness visual and hand feeling. When touched by hand, it was evaluated as good when it was smooth as bad. Strength was measured using a compressive strength tester. Measured porosity, flatness and strength are shown in Table 2 below.

In addition, the strength of the existing artificial marble plate on the market was measured and compared.

TABLE 2

division Assembly slag (% by weight) Fine slag (% by weight) Resin (wt%) Porosity (%) flatness Strength (㎏ / ㎠) Psalm 1 100 0 48 46.2 Bad 425 Psalm 2 95 5 45 43.5 Bad 523 Psalm 3 90 10 42 39.5 Bad 850 Psalm 4 85 15 40 37.3 Somewhat rough 980 Psalm 5 80 20 38 36.4 Good 995 Psalm 6 75 25 38 36.3 Good 1014 Psalm 7 70 30 38 36.5 Good 1010 Old artificial marble 320

In the results of Table 2, the surface flatness of the specimens 1 to 3 was good, but the color between the aggregates was large, so that the color was uneven, and in the case of specimen 1, the amount of resin added to yield good flatness exceeded 45 parts by weight. If the product is commercialized, the price may rise, which is not suitable.

<Example 3>                     

The base-forming mixture of the specimen 2 in Example 2 was charged into a mold preheated to 80-90 ° C., flattened and slightly cured by blowing hot air over the surface. A cosmetic layer formulation was charged onto the slightly hardened substrate surface, compression molded and cured to produce an integral multilayer artificial marble. Compression molding was carried out under the same conditions as in Example 2.

The decorative chip in the cosmetic layer formulation was prepared by mixing 70% by weight of unsaturated polyester, 30% by weight of calcium carbonate powder and 0.3% by weight of pigments of unsaturated polyester resin, followed by crushing to a size of 5 to 10 mm. As a pigment, the green and red pigment sold by the new company was purchased and used. 60 weight% of decorative chips and 40 weight% of polyester were mixed and used for forming a cosmetic layer.

Photographs of the surface and side cross-sections of the red and green multilayer marbles prepared in this example are shown in FIGS. 1A and 1B, respectively.

By the method of the present invention, artificial marble and multi-layer artificial marble having a beautiful appearance and excellent strength are produced at low cost.

Claims (9)

delete A mixture of 35 to 45 parts by weight of thermosetting resin per 100 parts by weight of a mixed slag of 70 to 85% by weight of steelmaking slag having a particle size of 1.18 to 3.35 mm and 15 to 30% by weight of fine steelmaking slag having a particle diameter of less than 1.18 mm was loaded into a mold and flattened. Thereafter, a mixture of 60 to 80% by weight of a decorative chip having a particle size of 1 to 10 mm and 20 to 40% by weight of a thermosetting resin was charged into the makeup layer and then hot pressed to prepare a multilayer artificial marble having a makeup layer before it was completely cured. How to. The method of claim 2, wherein the steelmaking slag is selected from the group consisting of converter slag, dephosphorous slag, de-silica slag, stainless slag, electro-oxidizer slag, electro-reduction reactor slag and mixtures thereof. How to. 3. The method of claim 2, wherein the decorative chip is a pulverized powder after hardening colored natural stone pulverized powder or calcium carbonate powder, pigment and thermosetting polymer resin mixture. The method of claim 2 or 4, wherein the thermosetting resin is polyester. A base layer formed by mixing 35 to 45 parts by weight of a mixed slag of 70 to 85% of steelmaking slag having a particle size of 1.18 to 3.35 mm and 15 to 30% by weight of fine steelmaking slag having a particle diameter of less than 1.18 mm, and 100 parts by weight of the thermosetting resin; And Cosmetic layer formed by mixing 60 to 80% by weight of decorative chips having a particle size of 1 to 10 mm and 20 to 40% by weight of thermosetting resin Duplex artificial marble comprising a. 7. The multilayer artificial marble according to claim 6, wherein the steelmaking slag is selected from the group consisting of converter slag, dephosphorous slag, de-silica slag, stainless slag, electro-oxidizer slag, electro-reduction reactor slag, and mixtures thereof. 7. The multilayer artificial marble according to claim 6, wherein the decorative chip is a pulverized product after hardening a colored natural stone pulverized product or calcium carbonate powder, a pigment, and a thermosetting polymer resin mixture. 9. The multilayer artificial marble according to claim 6 or 8, wherein the thermosetting resin is polyester.

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