KR101991685B1

KR101991685B1 - Artificial marble composition and method of manufactuing artificial marble using the same

Info

Publication number: KR101991685B1
Application number: KR1020150169665A
Authority: KR
Inventors: 남해림; 예성훈; 박환석; 김장순; 송예리; 김유준; 박민경
Original assignee: (주)엘지하우시스
Priority date: 2015-12-01
Filing date: 2015-12-01
Publication date: 2019-06-24
Also published as: KR20170064578A

Abstract

An artificial marble composition capable of realizing a pattern close to natural stone and a method for manufacturing artificial marble using the same are disclosed.
The artificial marble composition according to the present invention comprises a first resin mixture and a second resin mixture added to the first resin mixture and having a polarity different from that of the first resin mixture, Wherein the second resin mixture contains a base resin and an inorganic filler, wherein an additive having a dielectric constant of 3.5 to 5.5 is further added.

Description

TECHNICAL FIELD [0001] The present invention relates to an artificial marble composition and an artificial marble using the same,

The present invention relates to an artificial marble composition and a method for producing artificial marble using the same, and more particularly, to an artificial marble composition capable of realizing patterns similar to natural stones and a method for manufacturing artificial marble using the same.

Artificial marble is produced by mixing synthetic resin such as acrylic resin, unsaturated polyester resin and epoxy resin, or an additive such as natural stone powder, mineral and resin chip to a base such as cement or the like and adding additives such as pigments if necessary, It is a synthetic compound which realizes texture.

Representative types of artificial marble include acrylic artificial marble, polyester artificial marble, epoxy artificial marble, melamine artificial marble, and engineered stone-based artificial marble. Such artificial marble has a beautiful appearance and excellent workability, is lighter than natural marble, has excellent strength and is widely used as a counter table and various interior materials. Artificial marbles, which have been known up to now, have realized the appearance effect mainly through the combination of monochrome opaque chips. However, in such a manner, there is a limit to embody a pattern similar to natural marble or granite in artificial marble. Accordingly, much research is underway to develop artificial marble having an appearance similar to that of natural marble.

As a part of this, conventionally, in order to realize a pattern close to natural stone, a method of varying the shape of a chip, mixing or laminating resin mixtures of different colors in advance, and stirring with an agitator has been used. In addition, a mixture of different colors is injected through the movement of the nozzle to form a pattern.

However, when the shape of the chip is diversified, it does not have a connective pattern of natural stone. In the case of using a resin mixture of two colors, there is a disadvantage that there is no sharpness of the pattern of natural stone because of the smear caused by use of the same resin. Therefore, in order to realize a pattern similar to natural stone, it is necessary to control the sharpness of the dichroic resin mixture.

Related publications are disclosed in Korean Patent Laid-Open Publication No. 10-2008-0041501 (published on May 13, 2008), which describes a chip for artificial marble and a manufacturing method thereof.

It is an object of the present invention to provide an artificial marble composition which can improve the sharpness of a pattern so as to be close to natural stone by mixing marbles of two kinds of compounds having a polarity difference, and a method of manufacturing artificial marble using the artificial marble composition.

According to an aspect of the present invention, there is provided an artificial marble composition comprising a first resin mixture and a second resin mixture added to the first resin mixture and having a polarity different from that of the first resin mixture, Wherein each of the first and second resin mixtures comprises a base resin and an inorganic filler, and the second resin mixture further comprises an additive having a dielectric constant of 3.5 to 5.5.

According to an aspect of the present invention, there is provided a method for manufacturing artificial marble comprising: (a) casting a first resin mixture containing a base resin and an inorganic filler into a mold; (b) injecting or laminating a second resin mixture comprising a base resin, an inorganic filler and an additive having a dielectric constant of 3.5 to 5.5 into a mold molded with said first resin mixture; And (c) stirring the first and second resin mixtures with a stirrer to form a pattern, and then curing and sanding the resin mixture.

The artificial marble composition according to the present invention and the method of manufacturing artificial marble using the same are similar to those of the first and second resin mixtures so as to realize a marble pattern, 2 resin mixture is mixed with an additive having a dielectric constant of 3.5 to 5.5 so that the first and second resin mixtures have a polarity difference with each other and the polarity difference causes the mixing resistance between the first and second resin mixtures to be increased So that the sharpness of the pattern can be improved.

1 is a photograph showing a pattern of a sample prepared according to Example 1. Fig.
2 is a photograph showing a pattern of a sample prepared according to Example 2. Fig.
3 is a photograph showing a pattern of a sample prepared according to Comparative Example 1. Fig.

BRIEF DESCRIPTION OF THE DRAWINGS The advantages and features of the present invention and the manner of achieving them will become apparent with reference to the embodiments described in detail below with reference to the accompanying drawings. It should be understood, however, that the invention is not limited to the disclosed embodiments, but is capable of many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, To fully disclose the scope of the invention to those skilled in the art, and the invention is only defined by the scope of the claims. Like reference numerals refer to like elements throughout the specification.

Hereinafter, an artificial marble composition according to a preferred embodiment of the present invention and a method for manufacturing artificial marble using the same will be described in detail with reference to the accompanying drawings.

Artificial marble composition

An artificial marble composition according to an embodiment of the present invention is added to a first resin mixture and a first resin mixture and includes a second resin mixture having a polarity different from that of the first resin mixture.

At this time, each of the first and second resin mixtures includes a base resin and an inorganic filler, and the second resin mixture further contains an additive having a dielectric constant of 3.5 to 5.5.

That is, the artificial marble composition according to an embodiment of the present invention is prepared by mixing a mixture of homogeneous resins to have a pattern similar to natural stone, mixing additives having a dielectric constant of 3.5 to 5.5 with respect to one resin mixture, Thereby achieving superior pattern sharpness.

More specifically, when the first resin mixture and the second resin mixture are mixed by adding an additive having a dielectric constant of 3.5 to 5.5 to the second resin mixture so as to have a polarity difference with the first resin mixture, The additive having a dielectric constant of 3.5 to 5.5 added to the second resin mixture changes the overall polarity of the second resin mixture so as to be mixed with the first resin mixture It is possible to control the sharpness of the pattern by causing mixing resistance.

Therefore, the artificial marble composition according to the embodiment of the present invention uses the homogeneous resin as the first and second resin mixtures so as to realize a marble pattern, and the second resin By mixing an additive having a dielectric constant of 3.5 to 5.5 only for the mixture, the first and second resin mixtures have a polarity difference with each other. Due to such a polarity difference, the mixing resistance between the first and second resin mixtures is increased, Can be improved.

At this time, the first and second resin mixtures are preferably mixed in a weight ratio of 1: 1 to 10: 1. If the weight ratio of the first and second resin blend is less than 1: 1, the entire chip content is reduced, which is not similar to natural stone. On the contrary, when the weight ratio of the first and second resin mixture is more than 10: 1, there is a problem that a rich marble pattern can not be realized.

The first resin mixture contains 100 to 300 parts by weight of an inorganic filler per 100 parts by weight of the base resin. The second resin mixture includes 100 to 300 parts by weight of the inorganic filler and 5 to 20 parts by weight of the additive, based on 100 parts by weight of the base resin.

Each of the first and second resin mixtures may further contain at least one of a chip added at 10 to 100 parts by weight, an initiator added at 0.1 to 1 part by weight, and a catalyst added at 1 part by weight or less based on 100 parts by weight of the base resin .

The base resin added to each of the first and second resin mixtures includes 20 to 70 parts by weight of a polyacrylic resin, 30 to 80 parts by weight of an acryl-based, ester-based or styrene-based monomer, and 0.1 to 5 parts by weight of a polyfunctional monomer.

As the polymerizable monomer of the polyacrylic resin, an acrylic monomer, an ester monomer and a styrene monomer can be used, and among these, an acrylic monomer is preferably used. Specifically, examples of the acrylic monomer include acrylates such as methyl methacrylate (MMA), ethyl methacrylate (EMA), butyl methacrylate (BMA), 2-ethylhexyl methacrylate (EHMA), benzyl methacrylate Based monomers may be used, but the present invention is not limited thereto.

The polyfunctional monomer may be selected from among ethylene glycol dimethacrylate (EGDMA), 1,6-hexanediol diacrylate (HDDA), pentaerythritol triacrylate (PETIA) and trimethylolpropane triacrylate (TMPTMA) More than species may be used, but are not limited thereto.

As the inorganic filler, any of inorganic powders such as calcium carbonate, aluminum hydroxide, silica, alumina, magnesium hydroxide, and calcium aluminate may be used alone or in combination of two or more. The average particle size of the inorganic filler is preferably 1 to 100 mu m. When the average particle size of the inorganic filler is less than 1 탆, the viscosity of the resin mixture increases sharply. When the average particle size exceeds 100 탆, the inorganic material sinks due to the difference in specific gravity.

The inorganic filler is preferably added in an amount of 100 to 300 parts by weight based on 100 parts by weight of the base resin. When the amount of the inorganic filler to be added is less than 100 parts by weight based on 100 parts by weight of the base resin, there is a fear that an appropriate viscosity is not produced during the production process. On the other hand, when the amount of the inorganic filler to be added is more than 300 parts by weight based on 100 parts by weight of the base resin, the viscosity of the resin composition becomes excessively high, resulting in a decrease in moldability and a deterioration in heat processability.

The additive is intentionally added only to the second resin mixture in order to induce the first and second resin mixtures to be less intermixed and to improve the pattern sharpness. Thus, when the additive having the dielectric constant of 3.5 to 5.5 is mixed only with the second resin mixture so that the first and second resin mixtures of the same kind of resin are mixed with each other, the total polarity of the second resin mixture is changed by the additive Mixing resistance with the first resin mixture can be caused to improve the pattern sharpness.

Therefore, when the additive is mixed only with the second resin mixture in the first and second resin mixtures, it is possible to realize a sharp pattern even if the viscosity is low due to a high shear stess due to a high chip content during stirring .

Such an additive is preferably added in an amount of 5 to 20 parts by weight based on 100 parts by weight of the base resin. When the amount of the additive is less than 5 parts by weight based on 100 parts by weight of the base resin, the amount of the additive is insignificant, and there is a high possibility that the mixing resistance hardly exists. On the contrary, when the content of the additive is more than 20 parts by weight based on 100 parts by weight of the base resin, the mixing resistance increases and cracks may occur at the interfaces of the first and second resin mixtures. When the content of the non- There is a fear of lowering the strength.

The additives include dioctyl terephthalate, 2,2,4-trimethyl-1,3-pentadiol diisobutyrate (2,2,4-trimethyl-1,3-pentadiol diisobutyrate) containing at least one of an ester functional group, an ether functional group and an amine functional group , 4-trimethy-1,3-pentanediol diisobutyrate, 1,4-benzenedicarboxylic acid, bis-2 ethylhexyl ester, Any one selected from the group consisting of methyl tert-butyl ether, isopropyl ether, amyl ethyl ether and benzyl ethyl amine may be used.

It is preferable to use an additive having a molecular weight of 1,000 or less, because if the molecular weight of the additive exceeds 1,000, the viscosity of the additive may increase and the moldability may deteriorate.

The chip is added as a coloring means to represent the natural stone texture. It is preferable that such a chip uses a fine powder of 1 to 100 meshes. Specifically, any one of an acrylic chip, an epoxy chip, a styrene-based chip and a polyester-based chip may be used.

Such a chip is preferably added at a content ratio of 10 to 100 parts by weight based on 100 parts by weight of the base resin. When the addition amount of the chips is less than 10 parts by weight with respect to 100 parts by weight of the base resin, there is a great possibility that the coloring of the natural stone texture can not be achieved properly because the added amount thereof is insignificant. On the contrary, when the amount of the added chips exceeds 100 parts by weight with respect to 100 parts by weight of the base resin, there is a problem that moldability is lowered due to increase in viscosity.

The initiator can be used without limitation as long as it is used in polymerization of the polyacrylic resin, but it is preferable to use a peroxide initiator. Thus, the initiator may be selected from the group consisting of tertiary butyl cychclohexyl peroxydicarbonate, benzoyl peroxide, dicumyl peroxide, butyl hydroperoxide, cumyl hydroperoxide, t-butyl peroxymaleic acid, t-butyl hydroperoxide, It is preferable to use at least one of peroxide type initiators including oxides, lauroyl peroxide, azobisisobutyronitrile and azobisdimethylvaleronitrile.

Such an initiator is preferably added in an amount of 0.1 to 1 part by weight based on 100 parts by weight of the base resin.

The catalyst is added for the purpose of accelerating the polymerization rate. Such catalysts may be organic amines or organometallic salts.

Such a catalyst is preferably added at a content ratio of 1 part by weight or less based on 100 parts by weight of the base resin. If the addition amount of the catalyst is more than 1 part by weight based on 100 parts by weight of the base resin, it can not be economical because it can only increase the production cost compared to the effect increase.

Further, each of the first and second resin mixtures may contain, in addition to the above-mentioned components, a silicone-based or non-silicone-based defoaming agent within a range not affecting the effect of the present invention; Silane-based, acid-based or titanate-based coupling agents such as trimethoxysilane; An ultraviolet absorber such as phenyl salicylate, benzophenone, benzotriazole, nickel induction or radical scavenger; Halogen-based, phosphorus-based or inorganic-metal flame retardants; Stearic acid-based or silicone-based release agents; Catechol-based or hydroquinone-based polymerization inhibitors; And at least one selected from the group consisting of phenol type, amine type, quinone type, sulfur type or phosphorus type antioxidant.

How to make artificial marble

A method of manufacturing artificial marble according to an embodiment of the present invention will now be described.

First, a first resin mixture including a base resin and an inorganic filler is cast into a mold.

Next, a second resin mixture comprising a base resin, an inorganic filler and an additive having a dielectric constant of 3.5 to 5.5 is injected or laminated in a mold molded with the first resin mixture.

Next, the first and second resin mixtures are agitated by a stirrer to form a pattern, and then cured and sanded to produce artificial marble. At this time, the sanding treatment step is carried out to flatten the surface of the artificial marble so that the patterns contained in the artificial marble are more clearly displayed on the surface. By this sanding processing, .

A method of manufacturing artificial marble according to another embodiment of the present invention will now be described.

First, a first resin mixture containing a base resin and an inorganic filler is injected into a mold to mold the nozzle, which stores a second resin mixture including a base resin, an inorganic filler and an additive having a dielectric constant of 3.5 to 5.5, .

Next, the second resin mixture stored in the nozzle is dropped onto the first resin mixture to form a pattern, followed by hardening and sanding to produce artificial marble. At this time, the interval, the width, and the formation pattern of the stripe can be freely adjusted by injecting the second resin mixture stored in the nozzle into the first resin mixture.

First, a first resin mixture comprising a base resin and an inorganic filler is mixed with a second resin mixture comprising a base resin, an inorganic filler and an additive having a dielectric constant of 3.5 to 5.5 to form a composite resin mixture.

Next, the composite resin mixture is cast into a mold, molded and then subjected to a hardening and sanding treatment to produce artificial marble.

In the method of manufacturing artificial marble according to the above-described embodiments of the present invention, a homogeneous resin is used as a first and a second resin mixture so as to realize a marble pattern, 2 resin mixture is mixed with an additive having a dielectric constant of 3.5 to 5.5 so that the first and second resin mixtures have a polarity difference with each other and the polarity difference causes the mixing resistance between the first and second resin mixtures to be increased So that the sharpness of the pattern can be improved.

Example

Hereinafter, the configuration and operation of the present invention will be described in more detail with reference to preferred embodiments of the present invention. It is to be understood, however, that the same is by way of illustration and example only and is not to be construed in a limiting sense.

The contents not described here are sufficiently technically inferior to those skilled in the art, and a description thereof will be omitted.

1. Manufacture of artificial marble

Example 1

Preparation of first resin mixture

A first resin mixture was prepared by mixing 30 wt% of a base resin, 55 wt% of aluminum hydroxide having an average particle size of 20 mu m and 15 wt% of an acrylic chip. At this time, the base resin was composed of 30 wt% of polyacrylic resin, 67 wt% of methyl methacrylate (MMA), and 3 wt% of trimethylolpropane triacrylate (TMPTMA).

Preparation of second resin mixture

A second resin mixture was prepared by mixing 38 wt% of base resin, 60 wt% of aluminum hydroxide having an average particle size of 20 mu m and 2 wt% of additives having a dielectric constant of 4.5. At this time, the base resin was composed of 30 wt% of polyacrylic resin, 67 wt% of methyl methacrylate (MMA) and 3 wt% of trimethylolpropane triacrylate (TMPTMA), and the additive having a dielectric constant of 4.5 was 2,2 , 2,2,4-Trimethy-1,3-pentanediol diisobutyrate was used.

Manufacture of artificial marble

After the first resin mixture was cast into a mold, the second resin mixture was injected into the mold having the first resin mixture at a weight ratio of 7: 3. Next, the first and second resin mixtures were agitated 15 times with a rod having a diameter of 6 mm to form patterns, cured at 80 DEG C for 50 minutes, and then subjected to sanding treatment to produce artificial marble.

Example 2

Artificial marble was prepared in the same manner as in Example 1, except that 35 wt% of base resin, 60 wt% of aluminum hydroxide and 5 wt% of additives having a dielectric constant of 4.5 were mixed in the preparation of the second resin mixture.

Comparative Example 1

Artificial marble was prepared in the same manner as in Example 1 except that 35 wt% of base resin and 65 wt% of aluminum hydroxide were mixed in the preparation of the second resin mixture without adding additives.

2. Product pattern observation

FIGS. 1 and 2 are photographs showing patterns of samples prepared according to Examples 1 and 2, and FIG. 3 is a photograph showing patterns of samples prepared according to Comparative Example 1. FIG.

As shown in Figs. 1 and 2, in the case of artificial marble produced according to Examples 1 and 2, due to the mixing of the additive having a dielectric constant of 4.5 only for one compound of two compounds of the same kind of resin, And a clear pattern appears.

In contrast, as shown in FIG. 3, in the case of artificial marble produced according to Comparative Example 1, only two compounds of the same kind of resin were mixed without adding additives, and the pattern was blurred due to the pattern, I can confirm that this is not good.

Although the preferred embodiments of the present invention have been disclosed for illustrative purposes, those skilled in the art will appreciate that various modifications, additions and substitutions are possible, without departing from the scope and spirit of the invention as disclosed in the accompanying claims. These changes and modifications may be made without departing from the scope of the present invention. Accordingly, the scope of the present invention should be determined by the following claims.

Claims

And a second resin mixture added to the first resin mixture and the first resin mixture and having a polarity different from that of the first resin mixture,
Wherein each of the first and second resin mixtures comprises a base resin and an inorganic filler, wherein the second resin mixture further comprises an additive having a dielectric constant of 3.5 to 5.5,
Wherein the first resin mixture comprises 100 to 300 parts by weight of an inorganic filler based on 100 parts by weight of the base resin and the second resin mixture comprises 100 to 300 parts by weight of an inorganic filler and 100 to 300 parts by weight of an additive To 20 parts by weight,
Wherein an additive having a dielectric constant of 3.5 to 5.5 is added only to the second resin mixture so as to have a polarity difference between the first and second resin mixtures, Wherein the mixing resistance between the first and second resin mixtures is increased.

delete

The method according to claim 1,
The base resin
20 to 70 parts by weight of a polyacrylic resin, 30 to 80 parts by weight of an acryl-based, ester-based or styrene-based monomer, and 0.1 to 5 parts by weight of a polyfunctional monomer.

The method according to claim 1,
The inorganic filler
An artificial marble composition having an average particle size of 1 to 100 탆 and comprising at least one of calcium carbonate, aluminum hydroxide, silica, alumina, magnesium hydroxide and calcium aluminate.

The method according to claim 1,
Each of the first and second resin mixtures
With respect to 100 parts by weight of the base resin,
An initiator added in an amount of 0.1 to 1 part by weight, and a catalyst added in an amount of 1 part by weight or less.

6. The method of claim 5,
The chip
An acrylic-based chip, an epoxy-based chip, a styrene-based chip, and a polyester-based chip.

6. The method of claim 5,
The initiator
Butyl hydroperoxide, t-butyl hydroperoxide, t-butyl hydroperoxide, acetyl peroxide, lauroyl peroxide, t-butyl peroxydicarbonate, benzoyl peroxide, dicumyl peroxide, butyl hydroperoxide, cumyl hydroperoxide, Wherein the composition comprises at least one selected from the group consisting of peroxides, azobisisobutyronitrile, and azobisdimethylvaleronitrile.

6. The method of claim 5,
The catalyst
An organic amine or an organic metal salt.

The method according to claim 1,
The additive
Dioctyl terephthalate, 2,2,4-trimethyl-1,3-pentadiol diisobutyrate, which contains at least one of an ester functional group, an ether functional group and an amine functional group, 1,3-pentanediol diisobutyrate, 1,4-benzenedicarboxylic acid, bis-2 ethylhexyl ester, methyl tert- butyl ether, iso propyl ether, amyl ethyl ether, and benzyl ethyl amine.

The method according to claim 1,
The additive
An artificial marble composition having a molecular weight of 1,000 or less.

The method according to claim 1,
The first and second resin mixture
1: 1 to 10: 1.

(a) casting a first resin mixture containing a base resin and an inorganic filler into a mold to mold the first resin mixture;
(b) injecting or laminating a second resin mixture comprising a base resin, an inorganic filler and an additive having a dielectric constant of 3.5 to 5.5 into a mold molded with said first resin mixture; And
(c) stirring the first and second resin mixtures with a stirrer to form a pattern, and then curing and sanding the mixture,
Wherein the first resin mixture comprises 100 to 300 parts by weight of an inorganic filler based on 100 parts by weight of the base resin and the second resin mixture comprises 100 to 300 parts by weight of an inorganic filler and 100 to 300 parts by weight of an additive To 20 parts by weight,
Wherein an additive having a dielectric constant of 3.5 to 5.5 is added only to the second resin mixture so as to have a polarity difference between the first and second resin mixtures, Wherein the mixing resistance between the first and second resin mixtures is increased.

(a) injecting a first resin mixture comprising a base resin and an inorganic filler into a mold to mold a nozzle storing a second resin mixture including a base resin, an inorganic filler and an additive having a dielectric constant of 3.5 to 5.5, Aligning on top of the resin mixture; And
(b) dropping a second resin mixture stored in the nozzle onto the first resin mixture to form a pattern, and then curing and sanding the resin mixture,
Wherein the first resin mixture comprises 100 to 300 parts by weight of an inorganic filler based on 100 parts by weight of the base resin and the second resin mixture comprises 100 to 300 parts by weight of an inorganic filler and 100 to 300 parts by weight of an additive To 20 parts by weight,
Wherein an additive having a dielectric constant of 3.5 to 5.5 is added only to the second resin mixture so as to have a polarity difference between the first and second resin mixtures, Wherein the mixing resistance between the first and second resin mixtures is increased.

(a) mixing a first resin mixture comprising a base resin and an inorganic filler with a second resin mixture comprising a base resin, an inorganic filler and an additive having a dielectric constant of 3.5 to 5.5 to form a composite resin mixture; And
(b) casting the composite resin mixture into a mold, followed by curing and sanding,
Wherein the first resin mixture comprises 100 to 300 parts by weight of an inorganic filler based on 100 parts by weight of the base resin and the second resin mixture comprises 100 to 300 parts by weight of an inorganic filler and 100 to 300 parts by weight of an additive To 20 parts by weight,
Wherein an additive having a dielectric constant of 3.5 to 5.5 is added only to the second resin mixture so as to have a polarity difference between the first and second resin mixtures, Wherein the mixing resistance between the first and second resin mixtures is increased.