KR101986577B1 - Manufacturing method of artificial marble using stone dust - Google Patents

Abstract

The present invention relates to a method of manufacturing artificial marble using a stone, and more particularly, to a method for manufacturing a synthetic marble using a stone, comprising the steps of applying a coating agent for applying a coating agent to a rubber mold, applying an adhesive agent to the rubber mold to which the coating agent is applied through the coating agent application step A step of putting a stone into a rubber mold to which the adhesive is applied through the adhesive applying step, cooling the molded rubber after cooling it, a step of putting the stone mixture into the rubber mold into which the stone is put through the step of putting the stone into the mold, The mixture is injected, the gypsum mixture injected into the rubber mold through which the mixture of the gypsum mixture is injected is injected through the injection of the gypsum mixture, and the gypsum compounding agent is injected into the rubber mold, Followed by drying at room temperature.
The artificial marble produced through the above process exhibits a texture similar to that of natural marble by using a stone and a coating agent, but exhibits an advantage of being excellent in mechanical strength and light in weight.

Description

TECHNICAL FIELD [0001] The present invention relates to a manufacturing method of artificial marble using a stone,

More particularly, the present invention relates to a method for producing artificial marble using a stone and a coating agent, and more particularly, to a method for producing artificial marble using artificial marble, which exhibits a texture similar to that of natural marble and has excellent mechanical strength and light weight And a method for producing artificial marble.

In general, artificial marble is a term collectively referred to as an artificial composite in which a chip made of a synthetic resin is blended with a synthetic resin component, and various pigments, additives, and the like are mixed to realize a texture close to natural stone.

Such artificial marble is used as a finishing material for a kitchen, a wall, a washstand, various shelves, a floor, a porch, a staircase, and a bathtub. Chips are a very important factor in determining aesthetics in artificial marble, because they can express various textures using chips.

However, although artificial marble is mainly made of a synthetic resin chip and natural textures can be expressed using chips, the naturalness of the natural marble is limited in expressing the surface texture or the pattern because the artificial marble Since the chips to be used are dispersed and supplied relatively uniformly, there is a problem that even if the chip is partially exposed, the feeling of artificially processed is strong and the satisfaction of the consumer is low.

In order to solve the above problem, attempts have been made to express the stripes in such a manner that the base resin and the stripe resin are partially mixed and cured with the base color and the color difference being different from each other in size, color and material of the chip, There is a limit to expressing unspecific and irregular texture close to natural stone.

Korean Patent Registration No. 10-0989405 (October 15, 2010). Korean Patent Registration No. 10-0989406 (October 15, 2010).

An object of the present invention is to provide an artificial marble which shows a texture similar to that of natural marble using a stone and a coating agent, but also has excellent mechanical strength and light weight.

Another object of the present invention is to provide an artificial marble which not only exhibits adsorptivity and deodorization ability such as breathability and heavy metal, but also contains basalt and loess that emit far-infrared rays and negative ions, which are beneficial to the human body, and can enhance the health of the user.

An object of the present invention is to provide a rubber mold which comprises a step of applying a coating agent for applying a coating agent to a rubber mold, an application step of applying an adhesive to a rubber mold to which the coating agent is applied through the application of the coating agent, A step of introducing a stone mixture into the rubber mold to which the stone mixture has been added through the step of introducing the stone into the mold, heating the stone mixture to be cooled and then cooling the stone mold mixture, A step of charging a gypsum compounding agent into the inserted rubber mold and curing the gypsum compounding agent, and a drying step of separating the cured molded product from the rubber mold and then drying at room temperature. And a method for producing artificial marble using the same.

According to a preferred feature of the present invention, the coating agent application step is performed by coating a rubber mold with a coating agent in a thickness of 0.01 to 0.5 millimeter.

According to a further preferred feature of the present invention, the coating agent comprises 30 to 40% by weight of the lacquer composition and 60 to 70% by weight of the diluent.

According to a more preferred feature of the present invention, the adhesive applying step is performed by applying the adhesive to the rubber mold having the coating agent applied thereto through the coating agent applying step and drying it for 30 to 40 minutes two or three times.

According to an even more preferred feature of the present invention, the step of putting the stone into a rubber mold to which the adhesive has been applied through the adhesive applying step, the stone powder having an average particle size of 0.3 millimeter is introduced and heated to a temperature of 50 to 55 ° C A step of adding a first step of cooling to room temperature, and a step of introducing the first step, a step of putting a stone powder having an average particle size of 0.1 millimeter into a rubber mold into which the stone is put, heating it to a temperature of 50 to 55 ° C, And a second step of putting the stones.

According to a still further preferred feature of the present invention, the step of introducing the abrasive mixture is performed by charging the abrasive mixture into the rubber mold into which the abrasive has been introduced through the step of introducing the abrasive, heating the mixture at a temperature of 50 to 55 ° C, The abrasive mixture should be composed of 60 to 70% by weight of the abrasive, 20 to 30% by weight of the adhesive and 10% by weight of the water.

According to an even more preferred feature of the present invention, the adhesive comprises 75 to 85% by weight of a vinyl acetate resin emulsion and 15 to 25% by weight of water.

According to still another more preferred characteristic of the present invention, in the step of injecting the gypsum compounding agent, the gypsum compounding agent is applied to the rubber mold having the mixture of the gypsum mixture at a thickness of 4 millimeters through the step of injecting the gypsum mixture, and then the synthetic resin mesh is laminated and cured A gypsum compounding agent is applied to the upper surface of the laminated mesh to a thickness of 6 millimeters through the first gypsum compounding step and the first gypsum compounding step, and then a second gypsum compounding agent for laminating and curing the synthetic resin mesh And a third gypsum compounding step of applying a gypsum compounding agent to the upper surface of the stacked mesh through the second gypsum compounding step at a thickness of 3 millimeters.

According to a further preferred feature of the present invention, the gypsum compounding agent is composed of 40 to 45 wt% of gypsum powder for construction, 40 to 45 wt% of gypsum bond, and 10 to 20 wt% of water.

According to a further preferred feature of the present invention, the coating agent further contains 0.5 to 3 parts by weight of an additive composed of basalt or loess to 100 parts by weight of the coating agent.

The method of producing artificial marble using the stone according to the present invention exhibits an excellent effect of providing artificial marble having a mechanical strength similar to that of natural marble and light weight and light weight by using a stone and a coating agent.

In addition, it exhibits excellent effect of promoting user's health by containing basalt and loess that emits far infrared ray and anion which are beneficial to human body as well as adsorption power and deodorant power such as air permeability and heavy metal.

1 is a flowchart showing a method of manufacturing artificial marble using a stone according to the present invention.
FIG. 2 is a photograph showing artificial marble using the stone produced by Examples 1 to 3 of the present invention. FIG.

Hereinafter, preferred embodiments of the present invention and physical properties of the respective components will be described in detail with reference to the accompanying drawings. However, the present invention is not limited thereto, And this does not mean that the technical idea and scope of the present invention are limited.

A method of manufacturing artificial marble using a stone according to the present invention includes a coating step (S101) of applying a coating agent to a rubber mold, an adhesive applying step of applying an adhesive to a rubber mold coated with the coating agent through the coating agent applying step (S101) (S103); a step of inserting the stone into the rubber mold to which the adhesive is applied through the adhesive applying step (S103), heating the rubber mold after cooling it, and cooling the rubber mold; and a step of inserting the rubber mold (S107), a gypsum mixture injecting step (S107), a gypsum compounding agent is introduced into the rubber mold into which the gypsum mixture has been introduced, and the gypsum compounding agent is cured (S109), and drying step (S111) of separating the cured molding from the rubber mold and drying at room temperature through the gypsum compounding step (S109).

The step of applying the coating agent (S101) is a step of applying a coating agent to the rubber mold, and the coating agent is applied to the rubber mold to a thickness of 0.01 to 0.5 millimeter. In order to uniformly apply the gauzing agent to the rubber mold, It is preferable to apply the coating agent every 2 to 3 times.

The coating agent not only allows the artificial marble to be easily separated from the rubber mold, but also improves the gloss of the surface of the artificial marble to provide a surface texture similar to that of natural marble. When the coating agent is applied to less than 0.01 millimeter, The surface of the coating layer is easily damaged by the process of separating the artificial marble from the mold or the external force and the above effect can not be exhibited. When the coating agent is applied in a thickness of more than 0.5 mm, the transparency of the coating layer is lowered, Thereby deteriorating the quality.

In this case, the coating agent is composed of 30 to 40% by weight of the lacquer composition and 60 to 70% by weight of the diluent. The lacquer composition is not particularly limited as long as it exhibits excellent transparency and exhibits applicable properties to the surface of artificial marble. But it is preferably composed of an acrylate oligomer, a reactive diluent, a photopolymerization initiator and a cellulose derivative, and the product is commercially available from Aper 251 of Hepel.

The diluent is not particularly limited as long as it can dilute the lacquer composition of the component so as to exhibit a suitable viscosity with the coating agent. Any diluent may be used, but any diluent such as a lacquer for lacquer mixed with ethyl acetate, butanol, Is preferably used.

Also, the coating agent may further contain 0.5 to 3 parts by weight of an additive composed of basalt or loess to 100 parts by weight of the coating agent. The basalt and loess are preferably applied in the form of fine particles having a particle size of 0.01 to 0.05 mm The above-mentioned basalt and loess powder can provide an artificial marble which not only exhibits adsorptivity and deodorizing power such as air permeability and heavy metal, but also emits far infrared rays and anion which are beneficial to the human body, thereby improving the health of the user.

The adhesive applying step (S103) is a step of applying an adhesive to a rubber mold frame coated with the coating agent through the coating agent applying step (S101), and the adhesive is applied to the rubber mold frame coated with the coating agent through the coating adhesive applying step (S101) And drying for 30 to 40 minutes is repeated two or three times. The adhesive applied through the above process adheres to the coating layer and the stones introduced through the step of inserting the stones (S105).

When the adhesive is applied two or three times as described above, a uniform thickness adhesive layer is formed, and the coating layer is strongly adhered to the abrasive charged through the step of inserting the stone (S105).

At this time, the adhesive is composed of 75 to 85% by weight of a vinyl acetate resin emulsion and 15 to 25% by weight of water. Since the adhesive component comprising the above components strongly binds the coating layer and the above-mentioned abrasive grains and exhibits excellent transparency , Artificial marble with excellent surface quality, and 201 models of Ougong Bond are commercialized.

In the step S105 of applying the stone, the step of injecting the stone into the rubber mold with the adhesive applied through the adhesive applying step (S103), cooling the heated rubber after the heating, and the step of applying the adhesive through the adhesive applying step (S103) (S105-1) of charging a stone with an average particle size of 0.3 mm into a mold and heating it to a temperature of 50 to 55 DEG C and then cooling it to room temperature, and a step (S105-1) (Step S105-2) in which a stone powder having an average particle size of 0.1 millimeters is introduced into a rubber mold into which a stone is injected, heated to a temperature of 50 to 55 DEG C, and then cooled to room temperature .

It is preferable to shake off the adhesive component and the adhesive component after the first step of injecting the stone (S105-1) and the step of injecting the second stone (S105-2). In this case, When the first application of the stone and the second application of the stone with a particle size of 0.1 mm not only the surface pattern of the artificial marble becomes similar to the natural marble but also the particle size in the space between the stones having the particle size of 0.3 mm, And the surface texture of the artificial marble is further improved.

At this time, the above-mentioned limestone is not particularly limited as long as it can be made of artificial marble, and any kind can be used, but it is preferable that it is made of one selected from the group consisting of granite, marathon and silica sand.

In step S107, the step of injecting the stone into the rubber mold inserts the stone mixture into the rubber mold through the step of injecting the stone, heating and cooling the rubber mold, and the step of inserting the rubber The stone mixture is introduced into the mold by heating at a temperature of 50 to 55 DEG C and then cooled to room temperature. In the step of adding the stone mixture (S107), the stone mixture is introduced into the mold And the gypsum compounding agent.

Preferably, the abrasive mixture comprises 60 to 70% by weight of abrasive, 20 to 30% by weight of an adhesive, and 10% by weight of water. The abrasive is in a fine particle state with a particle size of 0.01 to 0.05 mm, Is the same as the adhesive component used in the coating step S103.

In the step S109 of injecting the gypsum compounding agent, a gypsum compounding agent is injected into the rubber mold into which the gypsum mixture is introduced through the step of injecting the gypsum mixture (S107), and the gypsum compounding agent is cured. A first gypsum compounding agent applying step S109-1 for applying a gypsum compounding agent to the inserted rubber mold to a thickness of 4 millimeters and then laminating and curing a synthetic resin mesh, a first gypsum compounding step S109-1, A second gypsum compounding step S109-2 in which a gypsum compounding agent is applied to the upper surface of the stacked mesh through a thickness of 6 mm to laminate and cure the synthetic resin mesh, and the second gypsum compounding step (S109-3) of applying a gypsum compounding agent to the upper surface of the stacked mesh through the third gypsum compounding agent (S109-2) to a thickness of 3 millimeters.

As described above, when the gypsum compounding agent is injected through the process of injecting the synthetic resin mesh in the middle of the gypsum compounding agent, the synthetic resin mesh acts as a framework like reinforcing bars of concrete. Therefore, The artificial marble having improved mechanical strength is provided.

At this time, it is preferable that the gypsum compounding agent is composed of 40 to 45 wt% of gypsum powder for construction, 40 to 45 wt% of gypsum bond and 10 to 20 wt% of water, and the gypsum powder for architectural use may be monodeco gypsum And the gypsum bond may be a KCC gypsum bond.

Most preferably, the gypsum powder for construction and the gypsum bond are used in a weight ratio of 1: 1. If the amount of the gypsum powder for construction is too low, the layer made of the gypsum compound shrinks excessively during the curing process, If the amount of the gypsum powder is too high, the amount of the gypsum bond relatively decreases and the impact resistance of the layer made of the compounding agent is lowered, which may deteriorate the mechanical properties of the artificial marble.

The drying step S111 is a step of separating the cured molding material from the rubber mold frame through the gypsum admixture injecting step S109 and then drying at a room temperature. The molding material cured through the gypsum compounding step S109 After separating from the rubber mold, it is dried at room temperature for 10 to 12 days.

Hereinafter, the method for producing artificial marble using the stone according to the present invention and the physical properties of the artificial marble produced through the method will be described with reference to examples.

≪ Example 1 >

A rubber mold was coated with a coating consisting of 30% by weight of a lacquer composition (Auro 251) and 70% by weight of a diluent (lacquer) in a thickness of 0.3 mm twice with a brush, and a rubber mold was coated with an adhesive Of 201) was sprayed twice to a thickness of 0.2 millimeter and dried for 35 minutes. After repeating the process twice, a granite powder (granite powder) having a particle size of 0.3 millimeter was put into a rubber mold to which the adhesive was applied (Granite powder) having a particle size of 0.1 millimeter was introduced and heated at a temperature of 53 DEG C, followed by shaking off the non-bonded abrasive. After that, 70% by weight of granite powder 0.03 mm in thickness, 30% by weight of pore bond 201 and 10% by weight of water as an adhesive) were charged and heated to a temperature of 53 캜 and then cooled to room temperature. 45% by weight of KCC gypsum bond and 10% by weight of water) was applied to a thickness of 4 mm, a synthetic resin mesh (dry bit) was laminated and cured, and the synthetic resin mesh The surface of the synthetic resin mesh is coated with a gypsum compounding agent to a thickness of 6 millimeters, a synthetic resin mesh is laminated and cured, a gypsum compounding agent is applied to the surface of the synthetic resin mesh to a thickness of 3 millimeters, And then dried at room temperature for 12 days to produce artificial marble using the stone.

≪ Example 2 >

Proceeding in the same manner as in Example 1, artificial marble using a stone was produced by using Marato as a stone.

≪ Example 3 >

Proceeding in the same manner as in Example 1, artificial marble was prepared by using quartz sand as a stone.

FIG. 2 is a photograph of the artificial marble using the stone produced in Example 1.

As shown in FIG. 2 below, artificial marble produced through Examples 1 to 3 of the present invention shows a surface texture and gloss similar to that of natural marble.

Accordingly, the method of manufacturing artificial marble using the stone according to the present invention provides artificial marble which shows a texture similar to that of natural marble and has excellent mechanical strength and light weight, by using a stone and a coating agent.

S101; Coating agent application step
S103; Adhesive application step
S105; Stoning step
S105-1; The first stone step
S105-2; Second Stone Step
S107; Step
S109; Gypsum compounding step
S109-1; The first gypsum compounding step
S109-2; The second gypsum compounding step
S109-3; Third Gypsum Blending Step
S111; Drying step

Claims (10)

delete delete Applying a coating agent for applying a coating agent to a rubber mold;
Applying an adhesive agent to the rubber mold to which the coating agent is applied through the coating agent application step;
A step of injecting the stone into the rubber mold to which the adhesive is applied through the adhesive applying step, and heating and cooling the stone mold;
A step of injecting a stone mixture into a rubber mold into which the stone powder is injected through the step of injecting the stone powder, and heating and cooling the stone powder mixture;
A step of injecting a gypsum compounding agent into the rubber mold into which the gypsum mixture is introduced through the step of introducing the gypsum mixture and curing the gypsum compounding agent; And
And a drying step of separating the cured molding from the rubber mold through the gypsum compounding step and drying at a room temperature,
Wherein the coating agent comprises 30 to 40% by weight of a lacquer composition and 60 to 70% by weight of a diluent.
Applying a coating agent for applying a coating agent to a rubber mold;
Applying an adhesive agent to the rubber mold to which the coating agent is applied through the coating agent application step;
A step of injecting the stone into the rubber mold to which the adhesive is applied through the adhesive applying step, and heating and cooling the stone mold;
A step of injecting a stone mixture into a rubber mold into which the stone powder is injected through the step of injecting the stone powder, and heating and cooling the stone powder mixture;
A step of injecting a gypsum compounding agent into the rubber mold into which the gypsum mixture is introduced through the step of introducing the gypsum mixture and curing the gypsum compounding agent; And
And a drying step of separating the cured molding from the rubber mold through the gypsum compounding step and drying at a room temperature,
Wherein the step of applying the adhesive comprises repeating the step of applying the adhesive to the rubber mold having the coating agent applied through the coating agent applying step and drying for 30 to 40 minutes 2 to 3 times. .
Applying a coating agent for applying a coating agent to a rubber mold;
Applying an adhesive agent to the rubber mold to which the coating agent is applied through the coating agent application step;
A step of injecting the stone into the rubber mold to which the adhesive is applied through the adhesive applying step, and heating and cooling the stone mold;
A step of injecting a stone mixture into a rubber mold into which the stone powder is injected through the step of injecting the stone powder, and heating and cooling the stone powder mixture;
A step of injecting a gypsum compounding agent into the rubber mold into which the gypsum mixture is introduced through the step of introducing the gypsum mixture and curing the gypsum compounding agent; And
And a drying step of separating the cured molding from the rubber mold through the gypsum compounding step and drying at a room temperature,
The step of injecting the stone inserts the stone into the rubber mold to which the adhesive has been applied through the adhesive applying step, the stone being injected with the average particle size of 0.3 millimeter, heated to a temperature of 50 to 55 占 폚 and then cooled to room temperature; And
And a second stone charging step of charging a stone mold having an average particle size of 0.1 millimeter into a rubber mold into which the stone is charged through the first stone charging step and heating it to a temperature of 50 to 55 DEG C and then cooling it to room temperature Characterized in that the method comprises the steps of:
Applying a coating agent for applying a coating agent to a rubber mold;
Applying an adhesive agent to the rubber mold to which the coating agent is applied through the coating agent application step;
A step of injecting the stone into the rubber mold to which the adhesive is applied through the adhesive applying step, and heating and cooling the stone mold;
A step of injecting a stone mixture into a rubber mold into which the stone powder is injected through the step of injecting the stone powder, and heating and cooling the stone powder mixture;
A step of injecting a gypsum compounding agent into the rubber mold into which the gypsum mixture is introduced through the step of introducing the gypsum mixture and curing the gypsum compounding agent; And
And a drying step of separating the cured molding from the rubber mold through the gypsum compounding step and drying at a room temperature,
The step of introducing the abrasive mixture may be carried out by charging the abrasive mixture into the rubber mold having the abrasive grains injected through the step of introducing the abrasive grains, heating the mixture at a temperature of 50 to 55 ° C,
Wherein the stone mixture comprises 60 to 70% by weight of limestone, 20 to 30% by weight of an adhesive, and 10% by weight of water.
delete Applying a coating agent for applying a coating agent to a rubber mold;
Applying an adhesive agent to the rubber mold to which the coating agent is applied through the coating agent application step;
A step of injecting the stone into the rubber mold to which the adhesive is applied through the adhesive applying step, and heating and cooling the stone mold;
A step of injecting a stone mixture into a rubber mold into which the stone powder is injected through the step of injecting the stone powder, and heating and cooling the stone powder mixture;
A step of injecting a gypsum compounding agent into the rubber mold into which the gypsum mixture is introduced through the step of introducing the gypsum mixture and curing the gypsum compounding agent; And
And a drying step of separating the cured molding from the rubber mold through the gypsum compounding step and drying at a room temperature,
The first gypsum compounding agent applying step of depositing a gypsum compounding agent in a thickness of 4 millimeters on a rubber mold into which the gypsum mixture is introduced through the step of adding the gypsum mixture, and then laminating and curing the synthetic resin mesh;
A second gypsum compounding agent applying step of depositing a gypsum compounding agent on the upper surface of the stacked mesh through the first gypsum compounding step to a thickness of 6 millimeters and then laminating and curing the synthetic resin mesh; And
And a third gypsum compounding agent applying step of applying a gypsum compounding agent to the upper surface of the stacked mesh through the second gypsum compounding step to a thickness of 3 millimeters. .
Applying a coating agent for applying a coating agent to a rubber mold;
Applying an adhesive agent to the rubber mold to which the coating agent is applied through the coating agent application step;
A step of injecting the stone into the rubber mold to which the adhesive is applied through the adhesive applying step, and heating and cooling the stone mold;
A step of injecting a stone mixture into a rubber mold into which the stone powder is injected through the step of injecting the stone powder, and heating and cooling the stone powder mixture;
A step of injecting a gypsum compounding agent into the rubber mold into which the gypsum mixture is introduced through the step of introducing the gypsum mixture and curing the gypsum compounding agent; And
And a drying step of separating the cured molding from the rubber mold through the gypsum compounding step and drying at a room temperature,
Wherein the gypsum compounding agent comprises 40 to 45% by weight of gypsum powder for construction, 40 to 45% by weight of gypsum bond, and 10 to 20% by weight of water.
The method of claim 3,
Wherein the coating agent further contains 0.5 to 3 parts by weight of an additive consisting of basalt or loess to 100 parts by weight of the coating agent.

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