KR101316304B1 - A transparent chip having binder layer, an artificial marbel comprising the same and preparation method thereof - Google Patents

Abstract

The present invention relates to a transparent chip, artificial marble comprising the above, and a method of manufacturing the same. The transparent chip of the present invention may include a transparent layer made of a material having high transparency and a light reflection layer formed under the transparent layer, thereby implementing transparency, depth, and glitter effect. In addition, the binder layer included in the transparent chip prevents chip peeling during the grinding process for manufacturing the chip of the light reflection layer or the manufacturing process of artificial marble, and stabilizes the interface between the base resin and the chip, thereby Defects can be prevented. As described above, the transparent chip of the present invention forms a light reflection layer that shows a sparkling effect on the underside of the transparent layer, thereby enabling the formation of a luxurious appearance pattern sparkling from the inside of artificial marble, and using existing methods such as casting or pressing. While also applied, there is an advantage that can prevent the failure of the chip or product.

Transparent layer, binder layer, UV coating layer, UV paint, light reflection layer, transparent chip, artificial marble

Description

A transparent chip having binder layer, an artificial marbel comprising the same and preparation method

The present invention is a transparent layer; A binder layer formed under the transparent layer; And it relates to a transparent chip comprising a light reflection layer formed on the lower portion of the binder layer, artificial marble comprising the above and a manufacturing method thereof.

Artificial marble generally refers to an artificial composite in which natural stone powder, minerals or additives such as resin chips are mixed with a base such as acrylic resin or cement to realize the texture of natural stone. Such acrylic artificial marble has a brilliant appearance and excellent processability compared to natural marble, and is widely used in sinks, countertops, and various interior materials. However, the artificial marble known to date has a limit in expressing a luxurious pattern close to natural marble or granite. In order to overcome these limitations, materials such as metal or mirrors have been used for acrylic artificial marble, but since the materials have high hardness, the use of them is extremely limited because of difficulty in polishing and processing.

Korean Laid-Open Patent Publication No. 2004-59913 discloses an acrylic artificial marble using a chip-in-chip. However, the above technique uses an inorganic filler in the manufacture of the chip. As a result, the overall transparency is lowered and the material constituting the glitter effect is located on the surface. Japanese Patent Laid-Open No. 2001-205750 discloses an artificial marble in which an intermediate layer containing a gloss pigment is formed between a transparent gel coat layer and an artificial marble. However, since the artificial marble disclosed in the above technique is simply coated with a gloss layer and a transparent layer on the surface, peeling phenomenon due to an external impact occurs easily, and thus there is a problem that durability of the product is reduced.

The present invention has been made in consideration of the above-described prior art, a transparent chip capable of producing excellent transparency, depth and glitter effect, and artificial marble comprising the above, and the above-mentioned which can prevent chip or product defects during manufacture. An object of the present invention is to provide a method for producing the same.

The present invention provides a transparent chip including a transparent layer, a binder layer formed under the transparent layer, and a light reflection layer formed under the binder layer as a means for solving the above problems.

The transparent layer of the transparent chip of the present invention preferably comprises at least one selected from the group consisting of acrylic resins, unsaturated polyester resins, epoxy resins, polyvinyl chloride resins, polystyrene resins and polycarbonate resins.

In the transparent chip, the transparent layer preferably has a light transmittance of 70 to 100%.

In addition, the binder layer in the transparent chip of the present invention is preferably a UV coating layer.

The transparent chip of the present invention also preferably includes a light reflecting layer at least one selected from the group consisting of metals, nonmetals, pearls and glass flakes.

The transparent chip also preferably further comprises a binder layer formed under the light reflection layer, preferably a UV coating layer.

The present invention is another means for solving the above problems, Base resin; And it provides an artificial marble comprising a transparent chip according to the present invention.

The transparent chip included in the artificial marble of the present invention preferably has a specific gravity difference of 2.0 or less from the base resin.

In addition, the transparent chip in the artificial marble is preferably included in an amount of 0.1 to 50 parts by weight based on 100 parts by weight of the base resin.

The present invention is another means for solving the above problems, the first step of producing a resin plate for a transparent layer; A second step of forming a binder layer on the flat plate manufactured in the first step; A third step of forming a light reflection layer on the binder layer formed in the second step; And a fourth step of grinding the flat plate on which the light reflection layer is formed in the third step.

The third step of the method for manufacturing a transparent chip of the present invention preferably further includes a step of forming a binder layer on the formed light reflection layer.

The present invention as another means for solving the above problems, (i) applying the transparent chip according to the invention to the raw material composition for artificial marble; And (ii) curing the raw material composition to which the transparent chip is applied.

Transparent chip of the present invention is a transparent layer made of a material having a high transparency (light transmittance); And including a light reflection layer formed on the lower transparent layer, it can produce an excellent transparency, depth and glitter effect in artificial marble. In addition, the binder layer included in the transparent chip prevents the peeling of the chip in the grinding process for manufacturing the chip or in the manufacturing process of artificial marble, and stabilizes the interface between the base resin and the chip, thereby preventing dichroism, chip or product of the pattern. Can be prevented. As described above, the transparent chip of the present invention forms a light reflection layer that shows a sparkling effect on the underside of the transparent layer, thereby enabling the formation of a luxurious appearance pattern sparkling from the inside of artificial marble, and using existing methods such as casting or pressing. While also applied, there is an advantage that can prevent the failure of the chip or product.

The present invention, a transparent layer; A binder layer formed under the transparent layer; And it relates to a transparent chip comprising a light reflection layer formed under the binder layer. The transparent chip of the present invention includes a light reflection layer formed under the transparent layer having a certain thickness, and has an advantage of producing a natural depth and sparkling effect in artificial marble. In addition, the transparent chip of the present invention includes a binder layer formed between the transparent layer and the light reflection layer, it is possible to prevent the peeling phenomenon of the chip and the loss of the product during processing.

Hereinafter, the transparent chip of the present invention will be described in more detail.

The material which comprises the transparent layer contained in the transparent chip of this invention is not specifically limited. For example, the transparent layer is an acrylic resin; Unsaturated polyester resins such as polyethylene terephthalate (PET); Epoxy resin; Polyvinyl chloride resin; Polystyrene resins; And it may be made of at least one transparent resin selected from the group consisting of polycarbonate resin, of which acrylic resin or unsaturated polyester resin is more preferred.

The transparent layer formed of the above material preferably has a light transmittance of 70 to 100%, preferably 90 to 100%. Most of the transparent chips known to date contain a large amount of inorganic fillers such as aluminum hydroxide, and since the transparent chips have a light transmittance of 60% or less, there is a limit to achieving excellent transparency. However, in the present invention, in order to realize sufficient and natural transparency, it is preferable that the transparent layer has a light transmittance in the above-described range without using a filler or by using a high transparency resin and a small amount of filler. The thickness of such a transparent layer is not specifically limited, What is necessary is just to select suitably according to the target depth.

The transparent chip of the present invention is characterized by including a binder layer under the transparent layer as described above. Such a binder layer improves the adhesion between the transparent layer and the light reflection layer to be described later, thereby preventing peeling or loss of the chip in the grinding process and / or the artificial marble manufacturing process. The material constituting the binder layer and the forming method are not particularly limited, and may be formed by a casting or pressing method using a general binder resin composition, but is more preferably a UV coating layer formed using a UV paint. UV coating is a coating method which forms a coating film by hardening a coating material by the ultraviolet energy which can collect a lot of energy from light in a short time. That is, the more energy a substance gives, the more difficult it is to break it down. For example, the paint cured at 500 ° C exists in a harder and more stable state than the paint cured at 60 ° C. However, since the deformation of the material occurs at high temperatures, there is a limit in the case of processing by heat. However, in the case of UV coating, there is an advantage that can form a very strong coating film by irradiating high energy instantaneously without changing the appearance. In general, when a metal material such as aluminum is directly deposited or transferred to the outside of a chip made of an acrylic resin or the like, there is a high possibility that a peeling phenomenon may occur due to an external impact, thereby exhibiting the effect of the metal deposition layer 100%. It is difficult to do this, and there is a high possibility of the loss caused by the dichroism of the appearance pattern or the defective chip. However, in the present invention, the above-mentioned problems can be solved through the formation of a binder layer, preferably a UV coating layer. In the present invention, the method of forming the binder layer is not particularly limited, and a casting or pressing method using a general binder resin may be used, and in the case of the UV coating layer, a general method using an acrylic or unsaturated polyester oligomer may be applied. Just do it.

The transparent chip of the present invention includes a light reflection layer formed under the binder layer. The light reflecting layer can give an excellent appearance effect to the artificial marble by giving a sparkling effect to the transparent chip. In addition, since the light reflection layer is formed under the transparent layer, it is recognized internally by a depth corresponding to the thickness of the transparent layer in the artificial marble, it is possible to produce a natural and excellent effect than the existing light reflection effect represented only on the surface layer. The type of material forming the light reflection layer is not particularly limited as long as it can reflect light and give a sparkling effect. For example, one or more selected from the group consisting of metals (ex. Gold, silver, copper, aluminum, nickel, etc.), base metals, pearls, and glass (ex. Glass flakes) may be used to form the light reflection layer. In the case of the metal or the non-metal, the light reflection layer may be formed by a conventional transfer or deposition method. In the case of pearl or glass flakes, the light reflection layer may be laminated and coated through a resin.

The transparent chip of the present invention may further include a binder layer, preferably a UV coating layer formed on the lower portion of the light reflection layer. By forming such an additional binder layer, it is possible to prevent disadvantages such as detachment of the light reflection layer during artificial marble processing, and to stabilize the interface between the base resin and the transparent chip of the artificial marble, thus performing the processing more smoothly. can do. Such a binder layer can be formed by the method as mentioned above, and the thickness etc. are not specifically limited, either.

The transparent chip of the present invention preferably has a specific gravity similar to that of the artificial marble, and specifically, has the same specific gravity as the artificial marble raw material composition, or preferably has a specific gravity difference of 0.2 or less. That is, the transparent chip of the present invention is preferably configured to have a specific gravity of 1.3 to 2.0, more preferably 1.4 to 1.8. If the specific gravity of the transparent chip is out of the above range, undesirable separation may occur inside the marble, or workability may be deteriorated.

In addition, the size of the transparent chip of the present invention is not particularly limited, for example, it is preferable to have a size of 2 to 20 mm. If the size of the transparent chip is out of the above range, there is a fear that the appearance effect and / or moldability, etc. are lowered.

The present invention also provides a base resin; And

It relates to an artificial marble comprising a transparent chip according to the present invention. By using the transparent chip of the present invention including a binder layer, there is an advantage that can prevent the increase of the deformation and defective rate of the product during the processing of artificial marble. That is, in the transparent chip of the present invention, the peeling phenomenon of the chip is prevented due to the binder layer formed between the transparent layer and the light reflection layer, and in some cases, the base resin of artificial marble due to the binder layer further formed under the light reflection layer. Stability with the interface with and can be further improved.

The kind of base resin contained in the artificial marble of the present invention is not particularly limited. That is, in the present invention, the base resin used for manufacturing various artificial marbles known in this field, such as acrylic, polyester, epoxy, melamine, and E-stone (engineered stone) artificial marble can be used without limitation. have. The term `` E-stone '' used above is made of natural stone, quartz, glass, mirror and inorganic fillers (ex. Aluminum hydroxide), etc., and is usually manufactured using resin syrup of 15% by weight or less based on the total weight. It means artificial marble. That is, the artificial marble of the present invention may include one or more base resins selected from the group consisting of acrylic resins, unsaturated polyester resins, epoxy resins, and melamine resins.

The specific kind of acrylic resin is not specifically limited in the above, For example, methyl (meth) acrylate, ethyl (meth) acrylate, butyl (meth) acrylate, 2-ethylhexyl (meth) acrylate, benzyl (meth) Polymers of one or more acrylic monomers selected from the group consisting of) acrylates and glycidyl (meth) acrylates.

In addition, the type of the unsaturated polyester is also not particularly limited, and is, for example, prepared by the condensation reaction of an α, β-unsaturated dibasic acid or a mixture of the dibasic acid and a saturated dibasic acid with a polyhydric alcohol. A polyester resin having a molecular weight of 1,000 to 5,000 can be used. At this time, the method for producing the polyester resin is not particularly limited. For example, the dibasic acid or the like is mixed with a polyhydric alcohol in a specific ratio (ex. Moles of alcoholic hydroxyl groups / moles of carboxyl groups = 0.8 to 1,2). Thereafter, the condensation reaction of the mixture is carried out at a temperature of 140 to 250 ° C. under an inert gas stream such as carbon dioxide gas and / or nitrogen gas, and thus the produced water may be removed and the temperature may be gradually increased according to the progress of the reaction.

Examples of the α, β-unsaturated dibasic acids or saturated dibasic acids used above include maleic anhydride, citraconic acid, fumaric acid, itaconic acid, and phthalic acid. acid), phthalic anhydride, isophthalic acid, terephthalic acid, succinic acid, adipic acid, sebacic acid and / or tetrahydrophthalic acid; Examples of polyhydric alcohols include ethylene glycol, diethylene glycol, triethylene glycol, propylene glycol, dipropylene glycol, tripropylene glycol, polypropylene glycol, 1,3-butylene glycol, hydrogenated bisphenol A, trimethylol propane monoaryl ether, Neopentyl glycol, 2,2,4-trimethyl-1,3-pentanediol and / or glycerin. The polyester resin may also be, if necessary, monobasic acids such as acrylic acid, propionic acid and / or benzoic acid; Or a polybasic acid such as trimellitic acid and / or tetracarboxylic acid of benzol.

In addition, the type of epoxy resin that can be used above is not particularly limited, and for example, a bifunctional or polyfunctional epoxy resin can be used. Examples of the bifunctional or polyfunctional epoxy resin include at least one selected from the group consisting of bisphenol A type epoxy resins, bisphenol S type epoxy resins, tetraphenyl ethane epoxy resins and phenol novolac type epoxy resins.

The artificial marble of the present invention includes the transparent chip of the present invention described above together with the base resin. At this time, the transparent chip has a specific gravity of 1.3 to 2.0, preferably 1.4 to 1.8, and preferably has the same specific gravity as that of the base resin, or a difference in specific gravity of 2.0 or less. If the difference in specific gravity with the base resin exceeds 2.0, there is a fear that separation of chips and the like may occur in the marble. In addition, the transparent chip is preferably included in an amount of 0.1 to 50 parts by weight based on 100 parts by weight of the base resin, but is not limited thereto.

The artificial marble of the present invention may also include inorganic fillers such as calcium carbonate, silica, metal hydroxides and alumina, to the extent that they affect the effects of the invention; Coupling agents; Crosslinking agents such as polyfunctional acrylic monomers; Initiator; Wetting agents; Reaction retardants; Crosslinking accelerators such as organic peroxides; Defoamer; General additives in the field of artificial marble, including ultraviolet stabilizers and organic or inorganic pigments or dyes.

Hereinafter, with reference to the accompanying drawings will be described in more detail with one aspect of the transparent chip and the artificial marble comprising the same. 1 is a cross-sectional view of a transparent chip according to an aspect of the present invention. As shown in FIG. 1, the transparent chip of the present invention may include a transparent layer 1, a UV coating layer 2, a light reflection layer 3, and a UV coating layer 4 sequentially formed. Figure 2 shows a cross-sectional view of the artificial marble to which the transparent chip as shown in Figure 1 (UV coating layer not shown). As shown in FIG. 2, in the artificial marble of the present invention, a light reflection layer 7 having a sparkling effect is formed under the transparent layer 5, and is recognized as being inside the thickness of the transparent layer 5. The marble (6) can produce a high-quality clarity, depth and glitter effect.

The present invention also comprises a first step of producing a resin plate for a transparent layer; A second step of forming a binder layer on the flat plate manufactured in the first step; A third step of forming a light reflection layer on the binder layer formed in the second step; And a fourth step of pulverizing the flat plate on which the light reflection layer is formed in the third step.

In the first step of the present invention, first, the resin composition is cured by a conventional method to prepare a resin plate for a transparent layer. At this time, the method of manufacturing a resin flat plate is not specifically limited, General methods, such as a casting method, a press method, a vibration vibration method, or a UV curing method, can be used.

In the present invention, the binder layer and the light reflection layer are sequentially formed after the first step. However, the process sequence is only one aspect of the present invention, and in the present invention, a method may be used in which the resin plate for the transparent layer and the plate for the light reflection layer are first manufactured, and then laminated with the binder layer. At this time, the method of forming a binder layer is not specifically limited, A conventional method can be used. For example, in the present invention, the binder layer may be formed through a casting or pressing method using a conventional binder resin composition, and in some cases, a liquid syrup and an UV curable monomer (ex. After applying a general UV paint including an acrylic monomer), a photoinitiator, a sensitizer, and other additives, a UV coating layer may be formed by irradiating UV rays and curing.

In addition, the method of forming the light reflection layer in the present invention is not particularly limited, for example, in the case of a metal or non-metal material, a transfer or vapor deposition method may be used, and in the case of pearl or glass flakes, the resin may be laminated through a resin.

In the manufacturing method of the present invention, the binder layer and the light reflection layer are sequentially formed on the transparent resin flat plate, and then, it is pulverized by a conventional method to manufacture a transparent chip. In addition, in the present invention, before crushing the flat plate in which the binder layer and the light reflection layer are sequentially formed, a process of forming an additional binder layer, preferably a UV coating layer under the formed light reflection layer may be further performed. By passing through such a process, the transparent chip in which the transparent layer, the binder layer, the light reflection layer, and the binder layer were formed one by one is possible.

The present invention also comprises the steps of: (i) applying the transparent chip according to the invention to the raw material composition for artificial marble; And (ii) curing the raw material composition to which the transparent chip is applied.

The raw material composition for artificial marble used in step (i) of the present invention can be prepared using the base resin described above, and the method is not particularly limited. For example, the raw material composition may be a resin syrup including the monomer and the high molecular weight (polymer or oligomer) and the like forming the base resin.

Step (ii) of the present invention is a step of curing the composition for the raw material to which the transparent chip is added, and at this time, a conventional method such as a casting method, a press method, a vibration vibration method, or a UV curing method may be used.

In the method of manufacturing the artificial marble of the present invention, after the curing step as described above, it may be further subjected to a post-treatment step of cutting and sanding the cured product to an appropriate size. Particularly, by sanding process, the transparent surface of the transparent chip, which may be included inside the artificial marble, is exposed to the surface of the marble, so that the natural transparency and the shimmering effect are realized, and the more luxurious appearance effect is applied to the artificial marble. It can be given.

Hereinafter, the present invention will be described in more detail through examples according to the present invention, but the scope of the present invention is not limited to the examples given below.

Example  One.

UV coating was performed on one surface of the acrylic plate manufactured by a conventional method, and then aluminum (Al) was deposited on the UV coating layer. Thereafter, UV coating was performed on the aluminum deposition layer to prepare a resin plate. The prepared flat plate was ground to various sizes to prepare a transparent chip, and the prepared transparent chip was mixed with a conventional acrylic resin syrup, cured, and then artificial marble was prepared by cutting and sanding. The transparent layer is located on the surface of the artificial marble prepared as described above, and the lower portion of the artificial marble was visually confirmed to be recognized as the aluminum deposition layer entered therein.

1 is a cross-sectional view of a transparent chip according to an aspect of the present invention.

2 is a cross-sectional view of the artificial marble including a transparent chip according to FIG.

≪ Description of reference numerals &

1: transparent layer 2: UV coating layer

3: light reflection layer 4: UV coating layer

5: transparent layer 6: artificial marble

7: light reflection layer

Claims (16)

Base resin and transparent chip, The transparent chip is a transparent layer; A binder layer formed under the transparent layer; And a light reflection layer formed below the binder layer, The binder layer is artificial marble which is a UV coating layer. The method of claim 1, The transparent layer is artificial marble, characterized in that it comprises at least one selected from the group consisting of acrylic resin, unsaturated polyester resin, epoxy resin, polyvinyl chloride resin, polystyrene resin and polycarbonate resin. The method of claim 1, Transparent layer is artificial marble, characterized in that the light transmittance is 70 to 100%. delete The method of claim 1, The light reflection layer is artificial marble, characterized in that it comprises one or more selected from the group consisting of metal, nonmetal, pearl and glass. The method of claim 1, Artificial marble further comprising a binder layer formed on the lower portion of the light reflection layer. The method of claim 6, Artificial marble, characterized in that the binder layer is a UV coating layer. The method of claim 1, Artificial marble, characterized in that the size of the transparent chip 2 to 20 mm. delete The method of claim 1, An artificial marble, wherein the base resin is at least one selected from the group consisting of acrylic resins, unsaturated polyester resins, epoxy resins, and melamine resins. The method of claim 1, Transparent chips are artificial marble, characterized in that the difference in specific gravity with the base resin is 2.0 or less. The method of claim 1, The transparent chip is artificial marble, characterized in that contained in an amount of 0.1 to 50 parts by weight based on 100 parts by weight of the base resin. The method of claim 1, Artificial marble, characterized in that it further comprises at least one selected from the group consisting of an inorganic filler, a crosslinking agent, a crosslinking accelerator, a pigment and a dye. delete delete (i) applying the transparent chip of claim 1 to the raw material composition for artificial marble; And (ii) a method of manufacturing artificial marble comprising the step of curing the raw material composition to which the transparent chip is applied.

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