KR20070023487A - Artificial marble containing transparent chip using co-extrusion and process for preparing the same - Google Patents

Abstract

The present invention relates to an artificial marble using a pellet-shaped transparent chip made of a resin composition containing a high-density filler and an outer marble made of a transparent resin composition using a coextrusion method and the like, and a method of manufacturing the same.

The present invention uses a transparent chip as a coloration chip in the manufacture of artificial marble, thereby solving the layer separation phenomenon of the transparent chip generated inside the artificial marble by the difference in specific gravity when using a single component of the transparent chip, It can be distinguished from artificial marble composed of monochromatic chip combinations, and can produce patterns closer to natural granite.

Coextrusion, Artificial Marble, Transparent Chip, Specific Gravity

Description

Artificial marble containing transparent chip using co-extrusion and process for preparing the same}

1 is a perspective view of a transparent chip for manufacturing artificial marble coated with a high specific gravity resin composition using a co-extrusion method according to an embodiment of the present invention.

2 is a manufacturing process diagram of a transparent chip for manufacturing artificial marble using co-extrusion according to an embodiment of the present invention.

3 is a cross-sectional view of the artificial marble cast using a transparent chip according to an embodiment of the present invention.

FIG. 4 is a cross-sectional view of the finished product of artificial marble in which the transparent chip is exposed to the surface by sanding after curing the artificial marble of FIG.

5 is a cross-sectional view of the artificial marble using a transparent chip of a conventional single component.

<Description of Symbols for Main Parts of Drawings>

1: transparent resin composition

2: main extruder

3: main extruder hopper

4: sub-extruder

5: sub-extruder hopper

6: high specific resin composition

7: cooler

8: cutting knife

9: Coextrusion Transparent Chip

10: inner layer (transparent layer)

11: outer layer (high specific floor)

12: sanded transparent chip

13: Existing Transparent Chip

The present invention relates to artificial marble and a method for manufacturing the same, and more particularly, using artificial marble using a pellet-shaped transparent chip formed of a high specific resin layer on the outer surface of the transparent inner resin layer using a coextrusion method, etc. It relates to a manufacturing method thereof.

Generally, artificial marble made of acrylic resin is widely used as a counter table and various interior materials due to its light appearance and superior strength compared to natural marble, as well as its beautiful appearance and excellent workability. The combination had technical limitations to express patterns similar to natural marble or granite.

Acrylic artificial marble is generally a syrup mixed with a monomer such as methyl methacrylate and polymethyl methacrylate, and fillers such as aluminum hydroxide, calcium carbonate and silica, and other pigments and hardeners. After mixing, it is manufactured by molding and curing in a mold or continuous steel belt.

Raw materials such as pigment and chip are used as a means of displaying marble shape and color of artificial marble, and the raw material composition of artificial marble to which the chip is applied by using the same resin as the artificial marble and adding pigment and filler, etc. After adjusting to have the same specific gravity as, and manufactured in the same process as artificial marble and then pulverized to produce a variety of colors and particle sizes.

Specifically, when the artificial marble is manufactured by applying the chip, inorganic fillers such as coal and aluminum hydroxide are used to maintain the same specific gravity as the base raw material of artificial marble in order to minimize layer separation due to the difference in specific gravity of the raw material itself. After adjusting the specific gravity by using a variety of pigments are prepared in the form of a flat plate and then pulverized chip is used.In this case, due to the filler component added to the raw material, the chip is opaque in the case of acryl-based natural granite or marble quartz (quartz) Transparent chips such as) cannot be produced.

In addition, when the transparent chip manufactured by using a transparent polymer of a single component without the addition of a filler is applied, there is a limitation of the size and input amount of the chip due to the phenomenon that the chip is separated by the specific gravity difference, thus quartz contained in the natural stone There was a technical limitation to more realistic reproduction of such transparent chips.

Republic of Korea Patent No. 491874 (A) 100 parts by weight of the artificial marble slurry consisting of 100 parts by weight of acrylic resin syrup, 120 to 200 parts by weight of inorganic filler, 2 to 10 parts by weight of crosslinking agent and 0.1 to 10 parts by weight of polymerization initiator, ( B) 100 parts by weight of the acrylic resin syrup, 100 to 150 parts by weight of the inorganic filler, 2 to 10 parts by weight of the crosslinking agent and 5 to 70 parts by weight of the marble chip consisting of 0.1 to 10 parts by weight of the initiator, wherein the inorganic filler mixing ratio of the artificial marble slurry is The artificial marble is characterized in that 20 to 50 parts by weight compared to the inorganic filler mixing ratio of the marble chip. However, in the case of this patent, the marble chip becomes an opaque chip as the inorganic filler is added to the acrylic resin, and thus, it is impossible to produce a transparent chip such as quartz of natural granite or marble.

Therefore, the present inventors, in order to overcome the above-described technical limitations, is composed of a transparent polymer resin such as acrylic resin or PET (polyethylene terephthalate) inside, coextrusion of a high specific weight resin layer including a filler on the outside After forming by using, the transparent chip itself obtained by cutting to maintain the specific gravity similar to the raw material composition of artificial marble, to reproduce the transparency, such as quartz and high-purity silica contained in natural stone to the existing opaque or translucent single It is about to develop artificial marble which is remarkably close to natural stone pattern and pattern compared to artificial marble applied with chip made of ingredients.

Therefore, the first technical problem of the present invention comprises a transparent resin layer inside the manufacture of artificial marble chip, the outside comprises a filler for controlling the specific gravity of the whole chip to the same specific gravity as the raw material composition of the artificial marble to which the chip is applied By constructing a high specific resin layer, it is to provide a transparent chip for manufacturing artificial marble with a completely improved layer separation phenomenon.

The second technical problem to be achieved by the present invention is to provide an artificial marble and a method of manufacturing the same, which are remarkably differentiated in natural marble and patterns and colors composed of the existing opaque chips by applying the transparent chip made as described above.

Hereinafter, the above and other objects of the present invention can be achieved by the configuration described below.

In order to achieve the above object, the present invention provides an artificial marble comprising a transparent inner layer and a transparent chip formed on an outer surface of the inner layer and having a specific gravity greater than that of the inner layer.

In the present invention, the specific gravity of the transparent chip is preferably equal to the specific gravity of the artificial marble raw material composition to which the chip is applied or its specific gravity difference is ± 0.2 g / cm 3 or less.

The present invention is characterized in that the specific gravity difference between the transparent chip and the artificial marble raw material composition to which the chip is applied is minimized, and there is no specific gravity difference between the transparent chip and the raw material composition, that is, the specific gravity is the same, and the specific gravity difference is If it is less than the above range chip separation did not occur.

In the present invention, to produce the artificial marble close to the natural stone in the pattern and color by reproducing the transparency, such as quartz and high purity silica contained in the natural stone, but introduced a transparent chip to the artificial marble raw material, in order to secure the transparency of the transparent chip As fillers are not added to base resins such as acrylic resins, separation of chips occurs due to specific gravity differences when chips are applied to artificial marble.

Specifically, the specific gravity of the plastic resin is generally 1.5 g / cm 3 or less, for example, the specific gravity of the transparent acrylic resin such as polymethyl methacrylate (PMMA) is approximately 1.17 to 1.20 g / cm 3. However, the specific gravity of the artificial marble raw material composition is generally about 1.4 to 1.8 g / cm 3.

As such, there is a difference in specific gravity between the transparent resin and the artificial marble raw material composition. When the transparent chip is manufactured from such a resin and applied to the artificial marble, separation of the transparent chip occurs. At present, there is no high specific gravity (more than 1.6 g / cm 3) transparent polymer and there is no artificial marble product to which a transparent chip is applied.

In the present invention, by forming a high specific weight outer layer on the surface of the transparent chip to minimize the specific gravity difference between the two raw materials, it is possible to produce the same effect as natural quartz without separation of the transparent chip.

In the present invention, the total specific gravity of the transparent chip is preferably 1.3 to 2.0 g / cm 3 similar to that of the artificial marble raw material composition, and the specific gravity of the outer layer is 1.5 to 10 g / cm 3 so that the specific gravity of the transparent chip reaches the above range. It is preferable.

In the present invention, the inner layer is a transparent layer having a light transmittance of 90 to 100%, preferably 95% or more. Conventional chips were translucent chips containing a filler such as aluminum hydroxide and having a light transmittance of 60% or less.

In the present invention, the resin used for the inner layer and the outer layer of the transparent chip is a transparent polymer resin such as acrylic resin (PMMA), polyester resin, polyethylene terephthalate (PET), and the like. It is preferable that it is a transparent acrylic chip.

According to the present invention, a transparent acrylic chip having excellent light transmittance and overall physical properties can be directly applied by introducing a high specific gravity layer, thereby not only securing natural reality by producing natural quartz chip effects. In addition, it is possible to apply post-processes such as casting and polishing, which were not applicable due to specific gravity differences.

In the present invention, the outer layer includes a filler for controlling the specific gravity of the transparent chip, and titanium dioxide, barium sulfate, aluminum hydroxide, calcium carbonate, silica, metal powder, metal salt, etc. may be used as a suitable filler. The specific gravity of the filler should be at least 2.5 g / cm 3 and the preferred specific gravity range is 2.5 to 10 g / cm 3. It is advantageous to use a high specific gravity filler to increase the specific gravity control effect.

In the present invention, a third layer such as an adhesive layer or a primer layer may be formed between the inner layer and the outer layer so as to improve the adhesive performance of both layers.

In the present invention, a pearl pigment may be added to the transparent layer, and when the pearl pigment is applied to the transparent layer, the pearl effect is excellent not only on the surface but also on the inside of the transparent layer. The pearl effect can be remarkably superior to the pearl effect of.

In the present invention, the shape of the transparent chip is not particularly limited, and may be, for example, a polyhedron such as a cylindrical or tetrahedron or a hexahedron. When manufacturing transparent chips using coextrusion, cylindrical and hexahedral shapes are common.

In the present invention, the outer layer may be formed in whole or in part on the outer surface of the inner layer, and when the transparent chip is manufactured using coextrusion, the outer layer is generally formed on the entire outer circumferential surface of the extrudate except for the cut surface.

In the present invention, in consideration of the appearance effect and formability, the size of the transparent chip is 3 to 20 mm, the amount of the transparent chip is preferably 1 to 50% by weight relative to the total amount of artificial marble.

In addition, the present invention comprises the steps of forming a transparent chip by cutting or pulverizing the outer layer having a specific gravity greater than the inner layer on the outer surface of the transparent inner layer; And it provides a method of manufacturing artificial marble comprising applying a transparent chip to the artificial marble raw material composition.

In the present invention, by adjusting the specific gravity and the amount of the filler added to the outer layer of the transparent chip, the specific gravity of the transparent chip can be adjusted to be equal to or close to the specific gravity of the artificial marble raw material composition.

In the present invention, the outer layer can be formed by coating, extrusion, injection or pressing, and a coextrusion method is particularly preferred.

In the present invention, a method of manufacturing a transparent chip using coextrusion may include preparing a resin composition for an inner layer and a resin composition for an outer layer having a specific gravity greater than that of the resin composition; Injecting each resin composition into an extruder, and then coextruding the outer layer to coat the outer layer; Cutting or pulverizing the coextruded extrudate to produce a transparent chip.

In the present invention, for the purpose of improving the adhesion of both layers between the inner layer and the outer layer, it may further comprise the step of forming an adhesive layer or a primer layer.

Thus, the present invention by applying a transparent chip formed with an outer layer made of a high specific gravity, it is possible to express the pattern closer to the appearance of natural granite than conventional acrylic artificial marble without separation of the transparent chip.

Hereinafter, the present invention will be described in detail with reference to the accompanying drawings.

1 is a perspective view of a transparent chip for manufacturing artificial marble coated with an internal transparent layer with a high specific weight resin composition using a coextrusion method according to an embodiment of the present invention, the transparent chip 9 is an internal transparent layer 10 and It consists of an outer high specific gravity layer (11). A third layer such as an adhesive layer or a primer layer may be formed between the transparent layer 10 and the high specific gravity layer 11 for the purpose of improving the adhesive performance of both layers.

As shown in FIG. 1, the shape of the transparent chip 9 may be a cylindrical body, a cube, a hexahedron, a pentagonal body, and the like, each of which has a circular cross section, a rectangle, and a triangular cross section. The shape of the transparent chip 9 may be changed in various ways without particular limitation. have. When manufacturing transparent chips using coextrusion, cylindrical and hexahedral shapes are common.

In addition, the outer layer 11 may be formed in whole or in part on the outer surface of the inner layer 10, the outer surface of the extrudate except for the cut surface as shown in Figures 1 and 2 when using the coextrusion It is common for layer 11 to be formed.

2 is a manufacturing process diagram of a transparent chip for manufacturing artificial marble using co-extrusion according to an embodiment of the present invention, the manufacturing process of the transparent chip 9 is a transparent resin composition such as conventional acrylic, polyester, PET (1) Co-extruding the composition (6) which is highly neutralized using the transparent resin and the high specific gravity filler on the outside; And pulverizing or cutting the extrudate for manufacturing the coextruded chip to produce a transparent chip 9.

The equipment for manufacturing the transparent chip 9 is a coextruder, which is a main extruder 2 forming the inner transparent layer 10, a main extruder hopper 3 into which the transparent resin composition 1 is introduced, and an outer high specific gravity layer ( 11) the sub-extruder (2) forming the sub-extruder hopper (5) into which the high-density resin composition (6) is introduced, the cooler (7) for cooling the co-extrusion, and the extrudate are cut to form a transparent chip (9). It consists of the cutting knife 8 for manufacturing.

In order to manufacture a transparent chip for artificial marble composed of two or more specific gravity according to the present invention, 0.1 to 1 parts by weight of an internal release agent for extrusion molding, based on 100 parts by weight of a transparent polymer having a light transmittance of 90% or more, such as an acrylic resin, If necessary, a transparent resin composition (1) for the internal transparent layer 10 including a pearl pigment is prepared, and a specific gravity including 0.1 to 200 parts by weight of a high specific gravity filler or metal powder for controlling specific gravity in the same resin as the transparent polymer. To prepare a high specific gravity resin composition (6) for the formation of the control outer coating layer (11). When the extrusion method and the polymer resin are used in the present invention, a crosslinking agent and a polymerization initiator are not used. Pigments can be added as needed.

The high specific gravity filler may have a particle size of 10 to 200 µm, and any one of inorganic powders having a specific gravity of 2.5 or more, such as titanium dioxide, metal salts, copper powder and iron powder, may be used. That is, if the specific gravity of the metal powder or metal salt, such as 2.5 or more can be applied, the higher the specific gravity can be excellent effect because the specific gravity can be adjusted by coating the internal transparent layer 10 in a small volume.

Titanium dioxide, barium sulfate, and general metal salts can be used as the filler that satisfies the above conditions. As the metal powder, ordinary metal powders such as copper powder (copper powder) and zinc powder can be used.

As the resin that can be used for the transparent chip 9, a conventional polymer compound capable of exhibiting a transparent effect such as PMMA and PET can be used, and an acrylic resin having excellent overall physical properties such as transparency is preferable.

Next, the raw material compositions 1 and 6 having different specific gravity are extruded through a coextruder. At this time, the molding temperature during extrusion is adjusted to 200 to 300 ℃, the molding speed is carried out extrusion molding at a level of 1 to 20 m / min.

The transparent resin composition (1) is introduced into the main extruder (2) through the main extruder hopper (3) and extruded to form an inner transparent layer (10), and a high specific gravity resin composition containing a high specific filler or metal powder (6) ) Is input to the sub-extruder (4) through the sub-extruder hopper (5) and extruded to form an outer high specific gravity layer (11).

The main extruder (2) may use a conventional extruder, the molding temperature is adjusted to be adjusted to 200 to 300 ℃, the extrusion speed is molded at 1 to 20 m / min, in the case of the auxiliary extruder (4) the main extruder It can extrude at the same temperature and molding speed as (2). The main extruder (2) and the sub-extruder (4) is not limited to a special facility, it is possible to utilize commonly known coextrusion facilities.

Next, the extrudate obtained through the extruder (2, 4) is cooled in the cooler (7), and then produced through the cutter (8) in the form of a transparent chip 9 of constant size, the same specific gravity as the base raw material of artificial marble Transparent chip 9 can be manufactured.

The diameter of the transparent chip 9 extruded by the above method is in the range of 3 to 20 mm, preferably 8 to 15 mm, and the cutting length is preferably in the range of 3 to 20 mm, preferably 5 to 12 mm. In this case, the coating thickness of the external high specific gravity layer 11 in the transparent chip 9 may be adjusted according to the specific gravity and the amount of the filler used.

Usually, the cutting size for determining the size of the transparent chip 9 is cut to a length of 5 to 12 mm using the cutter 8, and when used as a smaller chip, the required size after regrinding into chips cut to a certain length. Can be classified as

The coextrusion molding conditions can also be adjusted according to the molding characteristics of the resin, it can be molded by adjusting the same as the usual extrusion conditions.

The cross-sectional shape of the transparent chip 9 to be extruded can be designed into any shape that can be molded with an extruder, such as a circle, a triangle, a rectangle, and the like, and generally, shapes suitable for use as chips are round, square, and Designing in a triangular form can achieve good results in terms of appearance and effect when applied to the manufacture of artificial marble.

Next, the artificial marble transparent chip 9 prepared by the above method is added to the artificial marble formulation, mixed, and then molded to prepare an artificial marble plate as shown in FIG. 3. At this time, the input amount of the transparent chip 9 is 1 to 50 wt% based on the total amount of artificial marble raw material composition, 5 to 20 wt% is preferable in view of the appearance effect and moldability.

Next, the surface of the artificial marble plate is cured and then polished to produce a finished product of the artificial marble having the sanded transparent chip 12 exposed on the surface as shown in FIG. 4.

As a result of confirming the surface effect by hardening and polishing the acrylic artificial marble prepared as described above, as shown in FIG. 4, the separation of chips due to the difference in specific gravity does not occur and the transparent chip 9 is filled with filler or other By dispersing evenly with the chips, it is possible to create a transparent effect on the surface such as quartz of natural marble, thereby producing a pattern close to natural marble and granite.

On the other hand, as can be seen in Figure 5, in the case of the artificial marble using the transparent chip 13 of the conventional single component, the chip separation phenomenon in which the transparent chip 13 is separated by the difference in specific gravity with the filler or other chips occurs It was.

In Figs. 3 to 5, the small lumps of gray are conventional general chips.

EXAMPLE

0.5 parts by weight of zinc stearate (Zn-stearate) was added to 100 parts by weight of the acrylic resin as an internal mold release agent for extrusion molding to prepare an internal transparent resin composition, and then introduced into a main extruder hopper at a temperature of 250 ° C. and 5 m / min. Extrusion was performed to form an inner transparent layer (specific gravity: 1.19 g / cm 3, light transmittance: 95%).

In order to control the specific gravity of the transparent layer, 150 parts by weight of barium sulfate (density 4.499 g / cm 3), which is a high specific gravity filler, was added to 100 parts by weight of acrylic resin, and then co-extruded at the same temperature and molding speed as the main extruder. An outer layer (specific gravity 3.175 g / cm 3) was formed, and then molded and cooled through a extrusion mold manufactured to a diameter of 15 mm, cooled, and cut into a length of 12 mm to prepare a transparent chip for molding.

The specific gravity of the transparent chip manufactured in the above manner was 1.61 g / cm 3, and it was possible to obtain a good product without layer separation due to the difference in specific gravity (± 0.1 g / cm 3) by adding (10 wt%) of artificial marble.

Conventional acrylic artificial marble is made of a combination of opaque or translucent chips of various colors, which gives a monotonous feeling compared to natural stones because there is no chip material that can replace the transparent quartz or silica parts, especially with opaque or translucent chips. There was a limit in expressing color and pattern.

Therefore, in order to improve the above problems, by forming a high specific gravity resin layer outside the relatively low specific gravity transparent resin layer using a coextrusion method, the present invention ensures the same specific gravity as the existing artificial marble raw material composition and molding A transparent chip was produced to produce the effect of the transparent part of natural marble without causing layer separation due to the difference in specific gravity of the city.Using the transparent chip, an acrylic artificial marble was manufactured to produce a natural stone pattern unlike the existing artificial marble. It was remarkably similar to, and a luxurious effect was obtained.

Claims (17)

An artificial marble comprising a transparent inner layer and a transparent chip formed on an outer surface of the inner layer and having a greater specific gravity than the inner layer. The artificial marble according to claim 1, wherein the specific gravity of the transparent chip is the same as the specific gravity of the artificial marble raw material composition to which the chip is applied, or the specific gravity difference is ± 0.2 g / cm 3 or less. The artificial marble according to claim 1, wherein the specific gravity of the transparent chip is 1.3 to 2.0 g / cm 3. The artificial marble according to claim 1, wherein the specific gravity of the outer layer is 1.5 to 10 g / cm 3. The artificial marble according to claim 1, wherein the light transmittance of the inner layer is 90 to 100%. The artificial marble according to claim 1, wherein the base resin used for the inner layer and the outer layer is at least one selected from an acrylic resin, a polyester resin, and polyethylene terephthalate (PET). The artificial marble according to claim 1, wherein the inner layer is a transparent acrylic chip having an acrylic resin as a base resin. The artificial marble according to claim 1, wherein the outer layer comprises at least one filler selected from titanium dioxide, barium sulfate, aluminum hydroxide, calcium carbonate, silica, metal powder, and metal salt. The artificial marble according to claim 8, wherein the filler has a specific gravity of 2.5 to 10 g / cm 3. The artificial marble according to claim 1, wherein said inner layer comprises a pearl pigment. The artificial marble according to claim 1, wherein the transparent chip is a cylindrical or polyhedron. The artificial marble according to claim 1, wherein the outer layer is formed in whole or in part on an outer surface of the inner layer. The artificial marble according to claim 1, wherein the transparent chip has a size of 3 to 20 mm. The artificial marble according to claim 1, wherein the input amount of the transparent chip is 1 to 50% by weight relative to the total amount of artificial marble. Manufacturing an transparent chip by forming an outer layer having a specific gravity greater than that of the inner layer on an outer surface of the transparent inner layer and then cutting or pulverizing the inner layer; And A method of manufacturing artificial marble comprising applying a transparent chip to the artificial marble raw material composition. The method of claim 15, wherein the specific gravity of the transparent chip is adjusted to be equal to or close to the specific gravity of the artificial marble raw material composition by adjusting the specific gravity and the addition amount of the filler added to the outer layer. 16. The method of claim 15, wherein the resin composition for the inner layer and the outer layer is introduced into an extruder and coextruded to coat the outer layer on the outer surface of the inner layer.

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