KR101605584B1 - Artificial Marble Chip and Artificial Marble including Same - Google Patents

Abstract

The artificial marble chip according to the present invention comprises (a) a seed chip, (b) a first resin layer, and (c) a second resin layer, wherein the first resin layer (b) It is different in color from the resin layer (c). The artificial marble chip preferably has a ratio of minor axis to major axis of 1: 1 to 1: 1.5 and a specific gravity of 1.60 to 1.80. The artificial marble chip according to the present invention comprises the steps of: (A) preparing a seed chip; (B) vibrating the first resin layer on at least a part of the seed chip after mixing the seed chip into the first resin layer syrup; (C) vibrating the second resin layer on at least a part of the upper portion of the seed chip to which the first resin layer is applied after mixing the seed chip having the first resin layer applied thereto with the second resin layer syrup, and (D) The second resin layer is prepared by curing the applied seed chip. Further, the artificial marble according to the present invention comprises (a ') a curable resin matrix, (b') a curing resin, an inorganic filler and a pigment for artificial marble according to the present invention, and (c ') an inorganic filler. The artificial marble according to the present invention comprises the steps of (A ') preparing a composition for artificial marble by mixing the artificial marble chip, inorganic filler and additives of the present invention into a curable resin matrix, and (B') .

Description

Artificial Marble Chip and Artificial Marble Chip and Artificial Marble including Same

The present invention relates to artificial marble chips. More particularly, the present invention relates to an artificial marble chip having a seed layer and a resin layer different in color from a coating layer between the seed chip and the coating layer, and an artificial marble comprising the same.

Artificial marble is made by mixing additives such as natural stone powder, minerals and resin chips into a base such as acrylic resin, unsaturated polyester resin, epoxy resin or cement, and adding additives such as pigments if necessary, It is a composite.

Artificial marble is classified into granite product, which is made by adding solid product and chip. Representative types are acrylic artificial marble, polyester artificial marble, epoxy artificial marble, melamine artificial marble, And artificial marble of engineered stone series. Such artificial marble has a beautiful appearance and excellent workability, is lighter than natural marble and has excellent strength and is widely used as various interior and exterior materials such as various top plate materials, dressing table, sink, counter, wall material, have.

In order to realize a pattern close to natural stone or a new pattern which has not existed in the artificial marble chip manufacturing, various chips having different sizes, colors, materials and the like are used.

Conventional artificial marble chips were prepared by curing an acrylic resin composition to a plate state and then cutting or crushing the same with a rotary knife cutter and a crusher. Since the artificial marble chip thus manufactured has a sharp chip shape by cutting or crushing, a smooth pattern that can be felt in a circular shape and a natural pattern that can be felt in a variety of circular sizes can not be realized.

Korean Patent Publication No. 2011-0103227 discloses an artificial marble comprising a pebble-like chip and a method for manufacturing the same. However, since such artificial marble chips are produced by crushing a cured resin plate material to produce a seed chip, and then producing a seed chip by single layer coating with a resin syrup containing a pigment or a metal powder raw material, It is difficult to use it as an artificial marble chip because it is expressed on the seed chip.

Accordingly, the present inventors have found that, in order to prevent the color of the coating layer from being developed on the seed chip, a seed layer having a different color from the seed chip and the coating layer is added between the seed chip and the coating layer, Artificial marble chips and new artificial marbles containing them.

It is an object of the present invention to provide an artificial marble chip in which the color of the coating layer is not expressed on the seed chip, and the color of the seed chip and the coating layer can be distinguished.

Another object of the present invention is to provide a Pebble type artificial marble chip.

Another object of the present invention is to provide a multicolored artificial marble chip.

It is a further object of the present invention to provide artificial marble chips with a specific gravity of 1.60 to 1.80 of artificial marble chips, regardless of seed chip size.

Another object of the present invention is to provide artificial marble having a smooth pattern and a natural pattern including the chip for artificial marble of the present invention.

These and other objects of the present invention can be achieved by the present invention described below.

The artificial marble chip according to the present invention comprises (a) a seed chip, (b) a first resin layer, and (c) a second resin layer, wherein the first resin layer (b) And the second resin layer c is formed on at least a portion of the first resin layer b and the first resin layer b is formed on the seed chip a and the second resin layer c, The colors are different. The artificial marble chips are of the pebble type, and the ratio of the minor axis to the major axis of the cross section is 1: 1 to 1: 1.5, and the specific gravity is 1.60 to 1.80.

The seed chip (a) is composed of (a1) a seed chip resin and (a2) an inorganic filler. Wherein the inorganic filler (a2) is at least one selected from the group consisting of aluminum hydroxide, calcium hydroxide, silica, alumina, barium sulfate, hydroxide Magnesium, and mixtures thereof. The seed chip (a) is composed of 30 to 50% by weight of the seed chip resin (a1) and 50 to 70% by weight of the inorganic filler (a2). The seed chip (a) may further comprise (a3) a pigment or a dye.

The first resin layer (b) comprises (b1) a resin, (b2) an inorganic filler, and (b3) a pigment or a dye. The inorganic filler (b2) may be at least one selected from the group consisting of aluminum hydroxide, calcium hydroxide, silica, alumina, barium sulfate, magnesium hydroxide, and mixtures thereof. And the color of the pigment or dye (b3) is different from the color of the seed chip (a) and the second resin layer (c). The first resin layer (b) may further comprise (b4) a curing agent.

The second resin layer (c) comprises (c1) a resin, (c2) an inorganic filler, and (c3) a pigment or a dye. The inorganic filler (c2) may be at least one selected from the group consisting of aluminum hydroxide, calcium hydroxide, silica, alumina, barium sulfate, magnesium hydroxide, and mixtures thereof. And mixtures thereof. The second resin layer (c) may further comprise (c4) a curing agent.

The artificial marble chip of the present invention may further include a primer layer (d) between the seed chip (a) and the first resin layer (b). The primer layer (d) is composed of (d1) resin and (d2) curing agent. The resin (d1) is an unsaturated polyester resin, a polyurethane resin, an epoxy resin, a brominated epoxy acrylate resin and a mixture thereof.

(A) preparing a seed chip; (B) after mixing the seed chip with the first resin layer syrup, vibrating the first resin layer on at least a part of the upper part of the seed chip (C) vibrating the second resin layer on at least a part of the upper portion of the seed chip to which the first resin layer is applied, after mixing the seed chip coated with the first resin layer into the second resin layer syrup, and (D) curing the seed chip to which the second resin layer is applied.

The step (B) of vibrating the first resin layer and the step (C) of vibrating the second resin layer are applied with vibration for 10 to 30 minutes with a vibrator having a frequency of 1,000 to 100,000 vpm.

Step (D) of curing the seed chip to which the second resin layer is applied is performed at 50 to 200 캜.

The artificial marble chip manufacturing method of the present invention may further include a step of defoaming the seed chip to which the second resin layer is applied before curing.

The color of the first resin layer differs from the color of the seed chip and the second resin layer in the artificial marble chip manufactured according to the manufacturing method of the present invention.

The artificial marble according to the present invention is composed of (a ') a curable resin matrix, (b') a curing resin, an inorganic filler and a pigment for artificial marble of the present invention, and (c ') an inorganic filler.

The curable resin matrix (a ') is an acrylic resin, an unsaturated polyester resin, an epoxy resin, a polymer thereof, or a copolymer thereof.

The artificial marble of the present invention may further comprise (d ') a pigment or a dye. Further, the artificial marble of the present invention may contain a crosslinking agent, a polymerization initiator, a coupling agent, a curing accelerator, a flame retardant, an antistatic agent, an antibacterial agent, an antifoaming agent, a dispersant, a molecular weight regulator, an ultraviolet absorber, .

The artificial marble of the present invention comprises 100 parts by weight of a curable resin matrix (a '), 40 to 100 parts by weight of a chip (b') for artificial marble of the present invention, and 140 to 200 parts by weight of an inorganic filler (c ').

The method for producing artificial marble according to the present invention comprises the steps of (A ') preparing a composition for artificial marble by mixing a curable resin matrix with a chip for artificial marble of pebble type, an inorganic filler and an additive, and (B' And curing.

Step (B ') of curing the composition is carried out at 25 to 180 ° C.

The method of manufacturing artificial marble of the present invention may further include defoaming the composition before curing.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Reference will now be made in detail to the preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings.

The present invention provides a new multi-colored artificial marble chip having a pebble type, in which the color of the coating layer can not be expressed on the seed chip, the color of the seed chip and the coating layer can be distinguished, The present invention has the effect of providing an artificial marble having a natural pattern that can be felt in a variety of sizes and soft patterns that can be felt in the pebble type.

1 is a cross-sectional view of various artificial marble chips of the present invention.
2 is a photograph of an artificial marble chip according to Embodiment 1 of the present invention.
3 is a photograph of an artificial marble chip according to a second embodiment of the present invention.
4 is a photograph of an artificial marble chip according to Example 3 of the present invention.

The present invention relates to an artificial marble chip, and more particularly, to an artificial marble chip having a seed chip and a first resin layer differing in color from a second resin layer between the seed chip and the second resin layer, and a method for manufacturing the same.

Artificial marble chip

The artificial marble chip according to the present invention comprises (a) a seed chip, (b) a first resin layer, and (c) a second resin layer. Specifically, the first resin layer (b) is formed on at least a portion of the upper portion of the seed chip (a), and the second resin layer (c) is formed at least on the upper portion of the first resin layer (b). The color of the second resin layer (c) is not expressed on the seed chip (a) because the color of the first resin layer (b) is different from that of the seed chip (a) and the second resin layer .

The artificial marble chip of the present invention is of the pebble type and has a ratio of minor axis to major axis of 1: 1 to 1: 1.5, and specific gravity of 1.60 to 1.80.

(a) seed chip

The seed chip (a) is composed of (a1) a seed chip resin and (a2) an inorganic filler. The seed chip (a) is composed of 30 to 50% by weight of the seed chip resin (a1) and 50 to 70% by weight of the inorganic filler (a2). If the content of the resin (a1) for seed chips is less than 30% by weight, a seed chip can not be formed, and if it exceeds 50% by weight, it can not be included in a preferable specific gravity range of the artificial marble chips. By adjusting the content of the inorganic filler (b2), the specific gravity of the artificial marble chip can be adjusted to 1.60 to 1.80 irrespective of the size of the seed chip (a).

The resin (a1) for seed chips is an unsaturated polyester resin, a polyurethane resin, an epoxy resin, a brominated epoxy acrylate resin and a mixture thereof. An unsaturated polyester resin can be preferably used.

The inorganic filler (a2) is aluminum hydroxide, calcium hydroxide, silica, alumina, barium sulfate, magnesium hydroxide, and mixtures thereof. Preferably, aluminum hydroxide can be used. The inorganic filler (a2) has an average particle diameter of 10 to 100 mu m, preferably 10 to 30 mu m. When the average particle diameter is within the above range, the inorganic filler (a2) can be evenly dispersed in the seed chip resin (a1) and the inorganic filler (a2) can be evenly dispersed in the seed chip resin (a1) It is possible to prevent the transparency from deteriorating due to heat.

The seed chip (a) may further comprise (a3) a pigment or a dye. The pigment may be an inorganic pigment, an organic pigment, or the like. It is preferably used in such fields as a reddish brown pigment such as iron oxide, a yellow pigment such as iron hydroxide, a green pigment such as chromium oxide, a blue pigment such as sodium aluminosilicate, a white pigment such as titanium oxide and a black pigment such as carbon black And the like can be used. In addition, a metal material such as a metal thin film and a pearl may be included in order to impart a sparkling effect to the seed chip (a). The pigment or dye (a3) is 0.1 to 5.0 parts by weight based on 100 parts by weight of the seed chip resin (a1) and the inorganic filler (a2).

The seed chip (a) may further contain conventional additives such as an initiator, a crosslinking agent, a coupling agent, a surfactant, a curing accelerator, a flame retardant, an antistatic agent, an antibacterial agent, a defoaming agent, a dispersant, a molecular weight modifier, . The additive is 0.05 to 3.0 parts by weight based on 100 parts by weight of the seed chip resin (a1) and the inorganic filler (a2)

As the initiator, any peroxide initiator may be used without limitation, and specific examples include peroxides such as benzoyl peroxide, lauroyl peroxide, butyl hydroperoxide, cumyl hydroperoxide, and azo compounds such as azobisisobutyronitrile Can be used. Accelerators such as organometallic salts or organic amines which accelerate the polymerization rate can be used here.

As the crosslinking agent, polyfunctional methacrylate may be used. Specific examples thereof include ethylene glycol dimethacrylate, propylene glycol dimethacrylate, glycerol trimethacrylate, trimethylpropane trimethacrylate, and bisphenol A dimethacrylate , Tetraethylene glycol, dimethacrylate, 1,6-hexanediol dimethacrylate, polybutylene glycol, ethylene glycol dimethacrylate, diethylene glycol dimethacrylate, triethylene glycol dimethacrylate, and the like. Can be used.

When a coupling agent or a surfactant is used, the bonding force between the inorganic filler (a2) and the seed chip resin (a1) or the bonding force between the pigment (a3) and the seed chip resin (a1) can be improved. As the coupling agent, a silicate anhydride-based coupling agent can be used, and as the surfactant, an anionic surfactant or a nonionic surfactant can be used.

The seed chips (a) can be prepared by mixing the above components and curing them to prepare a resin plate material and crushing the same. The seed chip (a) thus produced has a major axis of 0.1 to 2.0 cm in cross section.

(b) the first resin layer

The present invention is characterized in that the seed chip (a) and the second resin layer (a) are formed so as to prevent the hue of the second resin layer (c) from being expressed on the seed chip (a) and to adjust the specific gravity of the artificial marble chip to 1.60 to 1.80 the first resin layer (b) can be formed between the first resin layer (c). The first resin layer (b) may be formed on at least a part of the upper part of the seed chip (a), that is, a part of the upper part of the seed chip (a), or may be formed entirely.

The first resin layer (b) comprises (b1) a resin, (b2) an inorganic filler, and (b3) a pigment or a dye. The first resin layer (b) comprises 9 to 25% by weight of resin (b1), 70 to 90% by weight of inorganic filler (b2) and 0.1 to 8% by weight of pigment or dye (b3).

The resin (b1) is an unsaturated polyester resin, a polyurethane resin, an epoxy resin, a brominated epoxy acrylate resin and a mixture thereof. An unsaturated polyester resin can be preferably used.

The inorganic filler (b2) is aluminum hydroxide, calcium hydroxide, silica, alumina, barium sulfate, magnesium hydroxide and mixtures thereof. Preferably, aluminum hydroxide can be used. The inorganic filler (b2) has an average particle diameter of 10 to 100 mu m, preferably 10 to 30 mu m. When the average particle diameter falls within the above range, the inorganic filler (b2) can be evenly dispersed in the resin (b1), and the transparency of the inorganic filler can be prevented from lowering as the inorganic filler (b2) .

By adjusting the content of the inorganic filler (b2), the specific gravity of the artificial marble chip can be adjusted to 1.60 to 1.80 irrespective of the size of the seed chip (a). Further, since the thickness of the first resin layer (b) increases as the content of the inorganic filler (b2) increases, the thickness of the first resin layer (b) can also be controlled by controlling the content of the inorganic filler (b2).

The pigment or dye (b3) may be an inorganic pigment, an organic pigment, a dye or the like. It is preferable to use a conventional white pigment used in this field such as titanium oxide to prevent the hue of the second resin layer (c) from being expressed in the seed layer (a). However, in order to prevent the hue of the second resin layer (c) from being expressed on the seed chip (a), a pigment or dye (b3) which is different in color from the seed chip (a) and the second resin layer . Further, it may include a metal material such as a metal thin film and a pearl to give a glare effect to the first resin layer (b).

Since the aluminum hydroxide is white and has high permeability with the inorganic filler (b2), the color of the second resin layer (c) can not be prevented from being expressed on the seed chip (a) when only aluminum hydroxide is used. It is preferable to use titanium oxide as the pigment or the dye (b3) in order to prevent the hue of the second resin layer (c) from being expressed on the seed chip (a) while using the inorganic filler (b2). The titanium oxide can prevent the hue of the second resin layer (c) from being expressed on the seed chip (a) by lowering the transmittance of the first resin layer.

The first resin layer (b) may further comprise (b4) a curing agent. As the curing agent (b4), conventional curing agents used in the artificial marble chip manufacturing can be used without limitation. The curing agent (b4) is 0.1 to 3.0 parts by weight based on 100 parts by weight of the resin (b1), the inorganic filler (b2), and the pigment or the dye (b3).

The artificial marble chip of the present invention comprises 5.0 to 10 parts by weight of the first resin layer (b) relative to 100 parts by weight of the seed chip (a). When the content of the first resin layer (b) is less than 5.0 parts by weight, the first resin layer can not coat the entire seed chip (a), so that the hue of the second resin layer (c) is expressed in the seed layer It is difficult to manufacture pebble-type artificial marble chips as a whole, and in the case of more than 10 parts by weight, bubbles are generated inside the coating, which causes a problem of stain resistance.

(c) a second resin layer

The present invention can produce a multi-colored artificial marble chip having a color different from that of the seed chip (a) and the first resin layer (b) by forming the second resin layer (c) Artificial marble chips can be manufactured. The second resin layer (c) is formed by partially removing at least a part of the upper part of the seed chip (a) in which the first resin layer (b) is at least partially formed, Or may be formed on the entire surface.

The second resin layer (c) comprises (c1) a resin, (c2) an inorganic filler, and (c3) a pigment or a dye. The second resin layer comprises 9 to 25% by weight of resin (c1), 70 to 90% by weight of inorganic filler (c2) and 0.1 to 5% by weight of pigment or dye (c3).

The resin (c1) is an unsaturated polyester resin, a polyurethane resin, an epoxy resin, a brominated epoxy acrylate resin and a mixture thereof. An unsaturated polyester resin can be preferably used.

The inorganic filler (c2) is aluminum hydroxide, calcium hydroxide, silica, alumina, barium sulfate, magnesium hydroxide, and mixtures thereof. Preferably, aluminum hydroxide can be used. The inorganic filler (c2) has an average particle diameter of 10 to 100 mu m, preferably 10 to 30 mu m. When the average particle diameter is within the above range, the inorganic filler c2 can be evenly dispersed in the resin c1 and the transparency of the inorganic filler can be prevented from being lowered as the inorganic filler c2 is evenly dispersed in the resin c1 .

The pigment or the dye (c3) may be an inorganic pigment, an organic pigment, a dye or the like. It is preferably used in such fields as a reddish brown pigment such as iron oxide, a yellow pigment such as iron hydroxide, a green pigment such as chromium oxide, a blue pigment such as sodium aluminosilicate, a white pigment such as titanium oxide and a black pigment such as carbon black And the like can be used. Further, it may include a metal material such as a metal thin film and a pearl to give a glare effect to the second resin layer (c).

The second resin layer (c) may further comprise (c4) a curing agent. As the curing agent (c4), conventional curing agents used in the artificial marble chip manufacturing can be used without limitation. The curing agent (c5) is 0.1 to 3.0 parts by weight based on 100 parts by weight of the resin (c1), the inorganic filler (c2) and the pigment or the dye (c3).

The artificial marble chip of the present invention comprises 5.0 to 10 parts by weight of the second resin layer (c) per 100 parts by weight of the seed chip (a). When the content of the second resin layer (c) is less than 5.0 parts by weight, the second resin layer can not coat the entire seed chip (a) coated with the first resin layer, making it difficult to produce artificial marble chips of the pebble type as a whole, If the amount is more than 10 parts by weight, bubbles are generated inside the coating, thereby causing a problem of stain resistance.

(d) a primer layer

The present invention is characterized in that a primer layer (a) is interposed between a seed chip (a) and a first resin layer (b) in order to reduce the occurrence of bubbles in an artificial marble chip and to improve the interfacial adhesion between the seed chip (a) and the first resin layer (d).

The primer layer (d) is composed of (d1) resin and (d2) curing agent. The primer layer (d) is composed of 95 to 99% by weight of the resin (d1) and 1 to 5% by weight of the curing agent (d2).

The resin (d1) is an unsaturated polyester resin, a polyurethane resin, an epoxy resin, a brominated epoxy acrylate resin and a mixture thereof. An unsaturated polyester resin can be preferably used.

The curing agent (d2) may be any conventional curing agent used in the artificial marble chip production.

The artificial marble chip of the present invention can further apply a vibration layer of a resin, an inorganic filler and a pigment or a dye layer on the second resin layer (c). When the resin layer is further applied with vibration, a multicolored artificial marble chip having a pebble type can be manufactured.

The artificial marble chip of the present invention has a ratio of the minor axis and the major axis of the cross section of 1: 1 to 1: 1.5, preferably 1: 1 to 1: 1.3, more preferably 1: 1 to 1: 1.1. If the ratio of the short axis to the major axis is within the above range, a pebble type artificial marble chip can be manufactured.

The artificial marble chip of the present invention has a specific gravity of 1.60 to 1.80. When the specific gravity of the artificial marble chips is within the above range, a desired pattern can be obtained in the production of artificial marble.

The artificial marble chip of the present invention has an average particle size of 0.1 to 2.0 cm. When the average grain size of the artificial marble chips is within the above range, the artificial marble may include a plurality of artificial marble chips physically separated from each other in the artificial marble matrix.

Manufacturing method of artificial marble chip

(A) preparing a seed chip; (B) after mixing the seed chip with the first resin layer syrup, vibrating the first resin layer on at least a part of the upper part of the seed chip (C) vibrating the second resin layer on at least a part of the upper portion of the seed chip to which the first resin layer is applied, after mixing the seed chip coated with the first resin layer into the second resin layer syrup, and (D) curing the seed chip to which the second resin layer is applied.

The step (B) of vibrating the first resin layer and the step (C) of vibrating the second resin layer may be performed by vibrating the upper and lower parts for a predetermined period of time in a closed space to form the first resin layer and the second resin layer Vibration application is performed.

The step (B) of vibrating the first resin layer and the step (C) of vibrating the second resin layer are applied with vibration for 10 to 30 minutes with a vibrator having a frequency of 1,000 to 100,000 vpm. Vibration application can be performed using general mechanical vibration or ultrasonic vibration. When the frequency is less than 1,000 vpm, the viscosity between the seed chip and the first resin layer syrup and the second resin layer syrup becomes low, and large and non-uniform bubbles are generated, so that the first resin layer and the second resin layer are not formed on the seed chip . The flowability of the seed chip, the first resin layer syrup and the second resin layer syrup is increased to separate the seed chip, the first resin layer syrup and the second resin layer syrup from each other, and the cracking phenomenon of the seed chip Occurs.

Through the vibration application, the first resin layer and the second resin layer are gradually and uniformly applied to the surface of the seed chip constituting the artificial marble chip of the pebble type so that the first resin layer and the second resin layer can be formed into a pebble type, Large and uneven bubbles are extracted and the pores are reduced by vibration application, so that unit volume mass, strength, durability and watertightness can be improved. In addition, artificial marble chips of a natural texture that can be felt in a variety of softness and average particle size felt in the pebble type can be manufactured.

The step (D) of curing the seed chip to which the second resin layer is applied is a step of curing the vibration-applied first resin layer and the second resin layer so that the materials in the first resin layer and the second resin layer are sealed And then curing at a constant temperature for a certain period of time. Step (D) of curing the seed chip to which the second resin layer is applied is performed at 50 to 200 캜.

The artificial marble chip manufacturing method of the present invention may further include a step of defoaming the seed chip to which the second resin layer is applied before curing. The defoaming step can be performed using a defoaming agent and can be performed under a vacuum of 760 mmHg.

The color of the first resin layer differs from the color of the seed chip and the second resin layer in the artificial marble chip produced according to the manufacturing method of the present invention.

The present invention relates to artificial marble, and relates to an artificial marble comprising a pebble type artificial marble chip.

Artificial marble

The artificial marble according to the present invention is composed of (a ') a curable resin matrix, (b') a curing resin, an inorganic filler and a pigment for artificial marble of the present invention, and (c ') an inorganic filler.

(a ') Curable resin matrix

The curable resin matrix (a ') is a component that occupies the background area of artificial marble and can be easily understood and manufactured by those skilled in the art.

The specific kind of the curable resin used for the matrix is not particularly limited. Examples of the curable resin include an acrylic resin, an unsaturated polyester resin, and an epoxy resin, and they can be used in the form of a polymer thereof, a copolymer thereof, or a mixture of two or more thereof. Among them, an acrylic resin may be preferably used.

Examples of the acrylic resin include acrylic acid, methyl acrylate, ethyl acrylate, isopropyl acrylate, n-butyl acrylate, 2-ethylhexyl acrylate, methacrylic acid, methyl methacrylate, ethyl methacrylate, N-butyl methacrylate, and 2-ethylhexyl methacrylate. Of these, methyl methacrylate can be preferably used.

The type of the unsaturated polyester resin is not particularly limited, and an unsaturated polyester resin produced through condensation reaction of a saturated or unsaturated dibasic acid and a polyhydric alcohol can be used. Examples of the saturated or unsaturated dibasic acids include maleic anhydride, citraconic acid, fumaric acid, itaconic acid, phthalic acid, phthalic anhydride, isophthalic acid, terephthalic acid, succinic acid, adipic acid, sebacic acid or tetrahydrophthalic acid. Polyhydric alcohols include ethylene glycol , Diethylene glycol, triethylene glycol, propylene glycol, dipropylene glycol, tripropylene glycol, polypropylene glycol, 1,3-butylene glycol, hydrogenated bisphenol A, trimethylolpropane monoaryl ether, neopentyl glycol, 2,2 , 4-trimethyl-1,3-pentadiol and / or glycerin. If necessary, a polybasic acid such as monobasic acid such as acrylic acid, propionic acid or benzoic acid or tetracarboxylic acid of trimellitic acid and benzol may be further used.

The type of the epoxy resin is not particularly limited, and specifically, a bifunctional or multifunctional epoxy resin can be used. Examples of the bifunctional or multifunctional epoxy resin include bisphenol A type epoxy resin, bisphenol S type epoxy resin, tetraphenyl ethane epoxy resin and phenol novolak type epoxy resin.

The curable resin is used in the form of a resin syrup obtained by dissolving a curable resin in a monomer, and the resin syrup includes a conventional monomer and a polymer. Examples of polymers include oligomers or polymers. For example, the acrylic resin syrup may include an acrylic monomer alone or a mixture of two or more thereof, and in some cases, a mixture of an acrylic monomer and a polymer in which a part thereof is polymerized. Specifically, the acrylic resin syrup is a resin syrup in which 65 to 95% by weight of an acrylic monomer and 5 to 35% by weight of an acrylic polymer as a polymer thereof are dissolved.

(b ') chip for artificial marble

The artificial marble of the present invention can include a smooth pattern that can be felt in the pebble type and a natural pattern that can be felt in a variety of sizes, including the artificial marble chip (b ') described above.

The artificial marble chip (b ') is made of a curable resin, an inorganic filler and a pigment. The artificial marble chip (b ') comprises a seed chip, a first resin layer and a second resin layer. In addition, it may further include a primer layer between the seed chip and the first resin layer, and may further include a resin layer on the second resin layer.

In one embodiment, the artificial marble chip (b ') is formed by applying a first resin layer made of a curable resin, an inorganic filler, a curing resin, an inorganic filler, and a pigment or a dye to a seed chip, Applying a second resin layer made of a curable resin, an inorganic filler and a pigment or a dye to the applied seed chip, and curing the second resin layer. The first resin layer and the second resin layer can be applied in a sealed space by applying vibration for a certain period of time and can be vibrated in a vibrator having a frequency of 1,000 to 100,000 vpm for 10 to 30 minutes. Further, the curing can be carried out at 50 to 200 ° C.

The ratio of the short axis to the major axis of the cross section of the artificial marble chip (b ') is 1: 1 to 1: 1.5, preferably 1: 1 to 1: 1.3, more preferably 1: to be. An artificial marble chip can be manufactured when the ratio of the short axis to the major axis is within the above range.

The artificial marble chip (b ') has a specific gravity of 1.60 to 1.80. When the specific gravity of the artificial marble chips is within the above range, a desired pattern can be obtained in the production of artificial marble.

The artificial marble chip (b ') has an average particle diameter of 0.1 to 2.0 cm. When the average grain size of the artificial marble chips is within the above range, the artificial marble may include a plurality of artificial marble chips physically separated from each other in the artificial marble matrix.

In addition to the artificial marble chip (b '), a conventional marble chip for artificial marble may be further included. A saturated polyester based marble chip may be used as the marble chip. Specifically, artificial marble marble chips are obtained by curing 100 parts by weight of an acrylic resin, 100 to 200 parts by weight of an inorganic filler, 0.1 to 10 parts by weight of a crosslinking agent and 0.1 to 10 parts by weight of an initiator, and they can be prepared by a conventional method.

The artificial marble chip (b ') of the present invention is preferably used in an amount of 40 to 100 parts by weight based on 100 parts by weight of the curable resin matrix.

(c ') inorganic filler

The inorganic filler (c ') may be an inorganic powder commonly used in the art such as calcium carbonate, aluminum hydroxide, silica, alumina, barium sulfate, and magnesium hydroxide. It is preferable that the inorganic powder has a size of 1 to 100 占 퐉, and among the inorganic powders, aluminum hydroxide is preferable in that it can produce artificial marble having a transparent and beautiful marble-like appearance.

The inorganic filler (c ') may be used in an amount of 140 to 200 parts by weight based on 100 parts by weight of the artificial marble matrix.

(d ') pigment or dye

The pigment may be an inorganic pigment, an organic pigment, a dye or the like. It is preferably used in such fields as a reddish brown pigment such as iron oxide, a yellow pigment such as iron hydroxide, a green pigment such as chromium oxide, a blue pigment such as sodium aluminosilicate, a white pigment such as titanium oxide and a black pigment such as carbon black And the like can be used. In addition, a metal material such as a metal thin film and a pearl may be included to impart a shiny effect to the seed chip (a ').

The pigment (d ') may be used in an amount of 0.0001 to 5.0 parts by weight based on 100 parts by weight of the resin matrix.

(e ') additive

The artificial marble of the present invention can be obtained by using one or more conventional additives such as an initiator, a crosslinking agent, a coupling agent, a surfactant, a curing accelerator, a flame retardant, an antistatic agent, an antibacterial agent, a defoaming agent, a dispersant, a molecular weight regulator, .

As the initiator, any peroxide initiator can be used without limitation, and specific examples thereof include peroxides such as benzoyl peroxide, lauroyl peroxide, butyl hydroperoxide, cumyl hydroperoxide, and azo compounds such as azobisisobutyronitrile Can be used. Accelerators such as organometallic salts or organic amines which accelerate the polymerization rate can be used here.

As the crosslinking agent, polyfunctional methacrylate may be used. Specific examples thereof include ethylene glycol dimethacrylate, propylene glycol dimethacrylate, glycerol trimethacrylate, trimethylpropane trimethacrylate, and bisphenol A dimethacrylate , Tetraethylene glycol, dimethacrylate, 1,6-hexanediol dimethacrylate, polybutylene glycol, ethylene glycol dimethacrylate, diethylene glycol dimethacrylate, triethylene glycol dimethacrylate, and the like. Can be used.

The coupling agent is for assisting the bonding between the inorganic filler and the resin, and can be easily carried out by a person having ordinary skill in the art to which the present invention belongs. Preferably, the coupling agent may be a silane coupling agent such as 3- (trimethoxycylyl) propylmethacrylate, vinyltrimethoxysilane or vinyltriethoxysilane. The coupling agent may be used in an amount of 0.1 to 1.0 part by weight based on 100 parts by weight of the resin matrix.

One embodiment of the artificial marble of the present invention is prepared by mixing 100 parts by weight of an artificial marble matrix obtained by curing an acrylic resin syrup, 40 to 100 parts by weight of a chip for artificial marble, 140 to 200 parts by weight of an inorganic filler and a small amount of other additives .

Manufacturing method of artificial marble

The artificial marble according to the present invention is prepared by mixing a curing resin matrix of the present invention with an artificial marble chip, an inorganic filler and an additive to prepare a composition for artificial marble and curing the composition at 25 to 180 ° C. The method may further include defoaming the composition prior to curing. The defoaming step may be performed using a defoaming agent and may be performed under a vacuum of 760 mmHg.

The composition for artificial marble is cured at 25 to 180 ° C. An amine or a sulfonic acid compound may be added together with a curing agent to control the curability, or a soap flame of copper, cobalt, potassium, calcium, zirconium or zinc may be added.

Specifically, the artificial marble of the present invention can be produced by mixing aluminum sulphate, pebble type artificial marble chips, trimethylpropane trimethacrylate, calcium hydroxide, n-dodecyl mercaptan, A composition prepared by mixing a defoaming agent, a dispersant, and a polymerization initiator is agitated, followed by vacuum defoaming and curing at a temperature of 80 ° C.

The present invention may be better understood by the following examples, which are for the purpose of illustrating the invention and are not intended to limit the scope of protection defined by the appended claims.

Example

Example  1 - artificial marble chip

To 100 parts by weight of MC801, an unsaturated polyester of Samhwa Painter, Perkadox 16, a di (4-tertiary-butylcyclohexyl) peroxydicarbonate from Akzo Nobel and tert-butylperoxy-2-ethylhexa 0.2 part by weight of an initiator obtained by mixing Trigonox 21 at a weight ratio of 1: 1 and 180 parts by weight of an inorganic filler HWF10 having a particle size of 10 mu m by Shandong Co., Ltd. were compounded, and the compound was cured Respectively. A cured product of various sizes having an average particle size of 0.1 to 2.0 cm and an average thickness of 0.1 to 1.0 cm was prepared using a PF-10 grinder manufactured by Sanya Engineering Co., Ltd. 100 parts by weight of the seed chip was placed in a Bulk Molding Compound kneader and 100 parts by weight of MC801, an unsaturated polyester of Samhwa Painter, was added to the di (4-tertiary-butylcyclohexyl) 0.2 parts by weight of an initiator obtained by mixing Perkadox 16, a peroxydicarbonate, and Trigonox 21, a tertiary-butylperoxy-2-ethylhexanoate available from Akzo Nobel at a weight ratio of 1: 1, 0.1 part by weight of Black 4T, 20 weight parts of resin syrup for the first resin layer mixed with 0.1 weight part of White 1024 were added little by little under the condition of being stirred by a Bulk Molding Compound kneader. After stirring for 10 minutes, 80 parts by weight of inorganic filler was added and stirred for 10 minutes again. The vibrator was taken out, and the vibration was applied for 20 minutes at a frequency of 5,000 vpm. After vibration application, the resultant was placed in a container and heated to 100 DEG C to cure it. The seed chips coated with the resin syrup were discharged to a cooling mixer and stirred until they were cooled to 15 to 40 캜, and artificial marble chips having an average particle size of 0.1 to 2.0 cm were prepared through a separator. 100 parts by weight of an artificial marble chip having an average particle diameter of 0.1 to 2.0 cm was placed in a Bulk Molding Compound kneader and 100 parts by weight of MC801, an unsaturated polyester of Samhwa Painter, 0.2 parts by weight of an initiator obtained by mixing Perkadox 16, a peroxydicarbonate, and Trigonox 21, a tertiary-butylperoxy-2-ethylhexanoate of Akzo Nobel, in a weight ratio of 1: 1, 20 parts by weight of a resin syrup for a second resin layer obtained by mixing 1.5 parts by weight of Dark Brown009 and 0.8 parts by weight of White 1024 were added little by little under the condition of being stirred by a Bulk Molding Compound kneader. After stirring for 10 minutes, 80 parts by weight of inorganic filler was added and stirred for 10 minutes again. The vibrator was taken out, and the vibration was applied for 20 minutes at a frequency of 5,000 vpm. After vibration application, the resultant was placed in a container and heated to 100 DEG C to cure it. The seed chips coated with the resin syrup were discharged to a cooling mixer, stirred until they were cooled to 15 to 40 캜, and then the average particle diameter was 0.1 to 2.0 cm through a separator. Using an electronic solid ratio meter SD-200L An artificial marble chip having a measured specific gravity of 1.67 was prepared. FIG. 1 shows a photograph of the artificial marble chip thus manufactured.

Example  2 - Artificial Marble Chip

The resin syrup for the second resin layer was prepared in the same manner as in Example 1, except that 0.5 parts by weight of Black 4T and 0.1 parts by weight of White 1024 were used instead of 1.5 parts by weight of Dark Brown 009 and 0.8 parts by weight of White 1024, An artificial marble chip having a particle size of 0.1 to 2.0 cm and a specific gravity of 1.68 as measured using an electronic solid ratio meter SD-200L of Yu-Yumi Co., Ltd. was prepared. FIG. 2 shows a photograph of the artificial marble chip thus manufactured.

Example  3 - artificial marble chips

In the resin syrup for the second resin layer, 1.0 part by weight of Black Silver 4T and 0.5 part by weight of Blue DF4 were used in place of 1.5 parts by weight of Dark Brown 009 and 0.8 parts by weight of White 1024 in the silver industry, Was applied in the same manner as in Example 1. < tb > < TABLE > The third resin layer was formed on the second resin layer by the following manufacturing method.

50 parts by weight of an artificial marble chip having a second resin layer formed therein was placed in a Bulk Molding Compound kneader and 100 parts by weight of MC801, an unsaturated polyester of Samhwa Painter Co., Ltd., -Butylcyclohexyl) peroxydicarbonate, and Trigonox 21, a tertiary-butylperoxy-2-ethylhexanoate available from Akzo Nobel, in a weight ratio of 1: 1, and 0.2 part by weight of White And 20 parts by weight of the resin syrup for the third resin layer mixed in 2 parts by weight of 1024 were added little by little under the condition of being stirred with a Bulk Molding Compound kneader. After stirring for 10 minutes, 100 parts by weight of the inorganic filler was added and stirred for 10 minutes again. The vibrator was taken out, and the vibration was applied for 20 minutes at a frequency of 5,000 vpm. After vibration application, the resultant was placed in a container and heated to 100 DEG C to cure it. The seed chips coated with the resin syrup were discharged to a cooling mixer, stirred until they were cooled to 15 to 40 캜, and then the average particle diameter was 0.1 to 2.0 cm through a separator. Using an electronic solid ratio meter SD-200L An artificial marble chip having a measured specific gravity of 1.69 was prepared. FIG. 3 shows a photograph of the artificial marble chip thus manufactured.

Comparative Example  1 - artificial marble chip

An artificial marble chip having an average particle diameter of 0.1 to 2.0 cm was produced in the same manner as in Example 1 except that the first resin layer was not formed in Example 1.

The photographs of the artificial marble chips of Examples 1 to 3 shown in Figs. 1 to 3 show that the first resin layer and the second resin layer are evenly applied to the seed chip to have a round shape, The color of the second resin layer is not expressed on the chip. On the other hand, in the artificial marble chip of Comparative Example 1, there exist seed chips not coated with the resin syrup, and artificial marble chips in which the color of the resin syrup is expressed on the seed chips are also present.

Example  4 - Artificial marble

100 parts by weight of the artificial marble chips prepared in Example 1 were mixed with 100 parts by weight of a resin syrup composed of 25% by weight of IH830 and 75% by weight of methyl methacrylate, polymethylmethacrylate of LG Corporation, HWF-10 160 parts by weight of trimethylolpropane trimethacrylate, 1.5 parts by weight of trimethylpropane trimethacrylate, 1.5 parts by weight of lauroyl peroxide, and hydroxyethyl methacrylate excipient phosphate as a phosphate-based coupling agent were mixed to prepare an artificial marble slurry. The manufactured artificial marble slurry was sprayed on a molding cell and then put into a hot air oven and the temperature of the oven was raised to 80 DEG C to cure the artificial marble slurry. After the curing was completed, the plate was cooled to room temperature to produce a plate-like artificial marble.

It will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention as defined by the appended claims.

Claims (30)

(a) a seed chip, (b) a first resin layer, (c) a second resin layer, and (d) a primer layer between the seed chip (a) and the first resin layer (b)
Wherein the first resin layer (b) is formed on at least a portion of an upper portion of the seed chip (a), the second resin layer (c) is formed on at least a portion of the upper portion of the first resin layer Wherein the resin layer (b) is different in color from the seed chip (a) and the second resin layer (c).
The artificial marble chip according to claim 1, wherein the artificial marble chip is a pebble type.
The artificial marble chip according to claim 1, wherein the artificial marble chip has a ratio of a minor axis to a major axis of a cross section of 1: 1 to 1: 5.
The artificial marble chip according to claim 1, wherein the artificial marble chip has a specific gravity of 1.60 to 1.80.
The seed chip according to claim 1, wherein the seed chip (a) comprises: (a1) a seed chip resin selected from the group consisting of an unsaturated polyester resin, a polyurethane resin, an epoxy resin, a brominated epoxy acrylate resin and a mixture thereof; And (a2) an inorganic filler selected from the group consisting of aluminum hydroxide, calcium hydroxide, silica, alumina, barium sulfate, magnesium hydroxide, and mixtures thereof.
The artificial marble chip according to claim 5, wherein the seed chip (a) comprises 30 to 50% by weight of the seed chip resin (a1) and 50 to 70% by weight of the inorganic filler (a2).
The seed chip (a) according to claim 5, wherein the seed chip (a) further comprises (a3) 0.1 to 5 parts by weight of a pigment or a dye relative to 100 parts by weight of the seed chip resin (a1) and the inorganic filler Artificial marble chips.
(B1) a resin selected from the group consisting of an unsaturated polyester resin, a polyurethane resin, an epoxy resin, a brominated epoxy acrylate resin and a mixture thereof; (b2) an inorganic filler selected from the group consisting of aluminum hydroxide, calcium hydroxide, silica, alumina, barium sulfate, magnesium hydroxide, and mixtures thereof; (b3) a pigment or dye having a color different from that of the seed chip (a) and the second resin layer (c).
The composition according to claim 8, wherein the first resin layer (b) comprises 9 to 25% by weight of the resin (b1), 70 to 90% by weight of the inorganic filler (b2) % ≪ / RTI > of the artificial marble chips.
The method of claim 8, wherein the first resin layer (b) comprises (b4) 0.1 to 3 wt.% Of a curing agent (b3) based on 100 parts by weight of the resin (b1), the inorganic filler (b2) And further comprising a portion of the artificial marble chip.
The resin composition according to claim 1, wherein the second resin layer (c) is a resin selected from the group consisting of (c1) an unsaturated polyester resin, a polyurethane resin, an epoxy resin, a brominated epoxy acrylate resin and a mixture thereof; (c2) an inorganic filler selected from the group consisting of aluminum hydroxide, calcium hydroxide, silica, alumina, barium sulfate, magnesium hydroxide, and mixtures thereof; And (c3) a pigment or a dye.
12. The composition according to claim 11, wherein the second resin layer (c) comprises from 9 to 25% by weight of the resin (c1), from 70 to 90% by weight of the inorganic filler (c2) and from 0.1 to 5% Wherein the artificial marble chip comprises:
12. The method according to claim 11, wherein the second resin layer (c) comprises 0.1 to 3 parts by weight of a curing agent (c4) relative to 100 parts by weight of the resin (c1), the inorganic filler (c2) Further comprising an artificial marble chip.
delete The method according to claim 1, wherein the primer layer (d) comprises: (d1) a resin selected from the group consisting of an unsaturated polyester resin, a polyurethane resin, an epoxy resin, a brominated epoxy acrylate resin and a mixture thereof; And (d2) a curing agent.
The artificial marble chip according to claim 15, wherein the primer layer (d) comprises 95 to 99% by weight of the resin (d1) and 1 to 5% by weight of the curing agent (d2).
(A) preparing a seed chip;
(B) forming a primer layer made of a resin selected from the group consisting of an unsaturated polyester resin, a polyurethane resin, an epoxy resin, a brominated epoxy acrylate resin, and a mixture thereof, and a curing agent on the seed chip;
(C) mixing the seed chip on which the primer layer is formed with the first resin layer syrup, and vibrating the first resin layer on at least a portion of the seed chip;
(D) mixing the seed chip coated with the first resin layer into the second resin layer syrup, and vibrating the second resin layer on at least a part of the seed chip coated with the first resin layer; And
(E) curing the seed chip to which the second resin layer is applied;
Wherein the method comprises the steps of:
18. The method of claim 17, wherein the first resin layer is different in color from the seed chip and the second resin layer.
The method according to claim 17, wherein the step (B) of vibrating the first resin layer and the step (C) of vibrating the second resin layer are performed by vibrating the vibrator with a vibration frequency of 1,000 to 100,000 vpm for 10 to 30 minutes Wherein the method comprises the steps of:
The method according to claim 17, wherein the seed chip coated with the second resin layer is cured at 50 to 200 캜.
18. The method of claim 17, further comprising defoaming the seed chips applied with the second resin layer before curing.
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