KR20090008678A - Artificial marble manufactured using crushed glasses and the manufacturing method thereof - Google Patents

Abstract

An artificial marble producing method using grinding glass is provided not to easily carrying off glass particles from a surface of the artificial marble by binding synthetic resin adhesive and grinding glass strongly and to cut down manufacturing cost. An artificial marble producing method using grinding glass comprises steps of: pulverizing the glass in order to particles less than 10mm; putting grinding glass into a mixer of an indirect heating method, heating the grinding glass at 100-200°C and forming micro hollows at a surface of grinding glass particles; mixing one or two or greater selected in epoxy, acryl or urethane to the glass particles and coating the surface of the glass particles; mixing one or two or greater selected from silica less than 1.0mm, silicon dioxide flower, limestone, gypsum, cement to coated glass particles; mixing cement and water with a mixture; injecting and molding the mixture in an artificial marble production mold frame; and curing a shaped artificial marble.

Description

Artificial Marble Manufactured Using Crushed Glasses and the Manufacturing Method Thereof}

The present invention relates to artificial marble that can be used as an interior, exterior wall or floor or sidewalk block of a building, and more particularly, to artificial marble using crushed glass, in particular crushed waste glass, and a method of manufacturing the same.

As the standard of living in our society improves, the demand for artificial marble is rapidly increasing. Natural marble has long been used as a symbol of nobility both east and west because of its luxurious texture and pattern. Artificial marble has a texture and pattern similar to that of natural marble, but because it is cheaper and easier to process than natural marble, it is widely used for interior, exterior walls, floors, and sometimes sidewalk blocks of buildings. Artificial marble may be classified into various types based on the materials used, and the present invention relates to artificial marble using crushed glass and a method of manufacturing the same.

The inventors have continued research on artificial marble since the 1990s, and in 1991, filed a patent application for "Manufacturing method of artificial marble surface-treated with colored bio-ceramic powder" and registered in 1996 (Patent No. 101669). In 1996, he filed a patent for "Manufacturing method of artificial marble" and was registered in 1998 (Patent No. 170611). This invention is the invention of the improvement of the artificial marble manufacturing method of patent No. 170611 which is the inventor of this invention especially.

Patent No. 170611, which is a related art, relates to a method of manufacturing artificial marble using pulverized waste glass, wherein 45-75 wt% of pulverized waste glass primarily contains 3-5 wt% of a synthetic resin adhesive which does not cause a chemical reaction with cement. Mixing, separately mixing 15-25 wt% cement, 0-25 wt% cement and 5-8 wt% water, followed by combining the primary and secondary mixtures again; Putting the mixture mixed in the process into a mold sprayed with a releasing agent, and vibrating and pressing the upper portion to produce a porous panel, and drying the panel in a drying state in a drying chamber by steam curing or atmospheric curing; Mixing the fine powdered stone powder with the unsaturated resin, spraying the mixture onto the dried porous panel so as to sufficiently infiltrate between the pores, and then drying and again curing the atmosphere; And removing the polished panel from the mold and manufacturing the final product. Artificial marble manufacturing method comprising a.

In general, there are two problems in the method of manufacturing artificial marble using crushed glass. First, it is difficult to manufacture artificial marble of thin plate because of the weak tensile strength, bending strength and compressive strength due to brittleness of the glass. The second is that the physical properties of the glass do not adhere well to other materials, and because of the weak binding force with other materials, artificial marble using crushed glass easily detaches glass particles from its surface.

Previous patent No. 170611 coated a surface of pulverized waste glass with a synthetic resin adhesive, and combined the pulverized waste glass coated with the synthetic resin adhesive with cement stone to manufacture a porous panel, and the unsaturated resin and high-molecular powder Alternatively, the mixture of cement was impregnated, and by using this method, the tensile strength, the bending strength and the compressive strength of the artificial marble were significantly improved, and thus, it was possible to manufacture artificial marble having a thickness of 2 cm or less.

However, even in this previous invention, there is still a weak binding of the glass and the synthetic resin adhesive, there is a problem that the glass particles are easily detached from the surface of artificial marble. In particular, when polishing the surface for the surface treatment of artificial marble, since the glass particles on the surface easily detached, the incidence of defective products was considerably high.

In addition, in the previous invention, a process of incorporating a mixture of unsaturated resin and high-molecular powder into the pores of the porous panel is required to improve tensile strength, flexural strength, and compressive strength. There is a problem that the process is complicated, the manufacturing cost is increased.

Due to these problems, artificial marble according to the invention of the previous patent No. 170611 has not been commercialized yet.

The present invention was devised to solve the above-mentioned problems of the present invention, and an object of the present invention is first, by strengthening the binding of the crushed glass and the synthetic resin adhesive in the artificial marble produced using the crushed glass, artificial marble It is to prevent the glass particles from easily detached from the surface of, and second, to simplify the manufacturing process, reduce the time required for manufacturing, and minimize the manufacturing cost in the artificial marble produced using the crushed glass.

The present invention can achieve the effect of recycling resources by industrially using the waste glass, and by using a lot of inexpensive materials such as waste glass and cement, compared to other kinds of artificial marble products, artificial marble at a significantly lower price There is an effect to provide, these effects can also be said to be included in the object of the present invention.

The present invention for achieving the above object is composed of the following steps.

First process: the process of grinding glass.

This process is a process of crushing glass so that it may become 10 mm or less particle | grains. When the size of the glass particles is increased, the total surface area is reduced to weaken binding with other materials, and there is a problem that the glass particles are easily detached from the surface in the final product.

When the artificial marble is to be made permeable, 100% of the glass particles pass through the 10 mm sieve and less than 10% of the 0.5 mm sieve may be used. On the other hand, if the artificial marble is to be made of water impermeability, it may be used to pass 100% in the 10mm sieve and 10% or more in the 0.5mm sieve. The more crushed glass with small particles (0.5 mm or less), the more impervious to water.

Second process: The process of heating the crushed glass particles by indirect heating method.

This process is to put the crushed glass in a mixer of the indirect heating method and heated to 100-200 ℃, to form a micro void on the surface of the crushed glass particles. As shown in FIG. 1, when the ground glass particles are heated to 100-200 ° C. by indirect heating, fine pores are formed on the surface of the glass (as a kind of crack), and the surface area of the ground glass particles is It greatly expands. In the case of the direct heating method, since the glass particles are melted, not only voids are formed on the surface of the glass particles, but also the surface area is reduced.

Third process: A process of mixing these materials into fine pores of glass particles by mixing epoxy, acrylic or urethane with crushed glass particles.

This process is a process of coating the surface of the glass particles while the epoxy pores, acrylic or urethane is added to the glass particles in which the micropores are formed on the surface thereof and mixed with these materials to fill the micropores of the glass particles. Since the surface area of the surface of the glass particles is greatly enlarged by the micropores, when the micropores are filled with epoxy or urethane, binding between the glass particles and epoxy, acryl or urethane is greatly enhanced.

Although glass has weak adhesive strength with other materials due to its physical properties, glass is filled with epoxy, acrylic, and urethane with strong adhesion to the micropores of the surface, and the glass particles are coated as they penetrate into the micropores of the glass particles. And the binding of these materials become very firm. It is preferable to add 0.01-0.05 parts by weight of epoxy, acrylic or urethane to be added in this step, based on 1 part by weight of crushed glass. If epoxy, acryl or urethane is added in an amount of 0.01 parts by weight or less, the coating solution may not be enough to coat the surface of the glass particles sufficiently, and the amount may be added in an amount of 0.05 parts by weight or more. Loss may occur. When the glass particles come together, it becomes difficult to uniformly mix the material and the glass particles introduced in the next step. At this stage, when there is a need for coloring, the pigments can be added and mixed. The amount of pigment used is preferably 10-50% by weight of the amount of epoxy or urethane.

Fourth process: silica sand, lime powder, limestone, gypsum, cement, etc. are injected into the glass particles coated on the surface and mixed.

This process is to add and mix 0.01-0.1 parts by weight of one or two selected from silica sand, lime powder, limestone, gypsum and cement with 1.0 mm (100 mesh) or less on glass particles coated with epoxy, acrylic or urethane. to be. The main purpose of injecting materials such as silica sand in this process is to increase the adhesion between the coated glass particles and the materials (such as cement) introduced in the next process. In addition, these materials also serve as a kind of filler. That is, since the silica sand of the present process is relatively large in size, when they bind with the coated glass particles, the surface area of the coated glass particles is widened. Therefore, the adhesion between the cement and the coated glass particles introduced in the next process is increased. Is improved.

The reason for limiting the particle size of the material such as silica sand introduced in the present process to 1.0 mm or less is that when it is 1.0 mm or more, it can be easily detached by external impact even after binding with glass. In this step, it is necessary to sufficiently mix the mixture. If the mixture is not sufficiently mixed, the glass particles are more likely to aggregate together, and the strength of the aggregated portion of the glass particles may be weak, and the appearance of the artificial marble may not be beautiful. .

Fifth process: The process of adding and mixing cement, water, and various materials such as admixture, pigment, reinforcing fiber, water-soluble resin, loess, charcoal, mica, silica sand and color stone to the mixture of electric process.

This process is just before the next molding process, in which the mixed mixture in the electrical process is kept at a high temperature, basically 0.1-0.3 parts by weight of cement and 0.02-0.1 parts by weight of water are mixed, and various materials as necessary. It is a process that can be mixed with them. Materials to be mixed as necessary, pigments for coloring, reinforcing fibers for reinforcing tensile strength, charcoal for humidity control, sterilization and coloring, and yellow soil for far-infrared rays. Can be added. Of course, a variety of materials can be introduced at this stage, including mica, silica, and colorstones (except for those that do not match the properties of artificial marble).

Sixth process: The process of molding the mixture of electric process into the mold of artificial marble.

This step is a step of molding the mixture of the above step into a predetermined shape by adding, vibrating, and pressing the mixture to a predetermined mold. The molding method is, as usual, sputtering a mold release agent into a mold made of plastic, wood, iron plate or the like, and then molding by adding, vibrating and pressing the mixture of the electric process.

Seventh, the process of completing the molded artificial marble into the final product.

This process is to finish the artificial marble formed in the electrical process to the final product, there are three ways. The first method is to cure in the curing room as it is molded, and the second method is to sprinkle over 30% of the coated glass particles by sprinkling on the surface of the artificial marble formed in the electrical stage in order to save natural beauty, and to cure. Third, the surface of the artificial marble is polished by polishing the surface of the artificial marble cured in the curing chamber using one or more selected from diamond abrasive, resin abrasive, ceramic abrasive, fiber, and cellum oxide. .

In order to cure artificial marble, the artificial marble formed in the electrical process is first cured without removing the mold (the state contained in the mold), and the artificial marble is separated from the mold when the molded shape can be sufficiently maintained. It is preferable to use it by the method of making room temperature curing, and to use, after fully curing so that it may be 5,000 or more (time x temperature). If the product is not sufficiently cured, the product may be easily broken or deformed.

The present invention, as shown above, may be applied to the manufacture of panels of artificial marble, but may also be used to manufacture blocks in which a cement concrete layer is bonded to the bottom thereof. In the manufacture of the block, in the case of bonding the cement concrete layer to the lower portion of the artificial marble layer, a conventional block manufacturing method composed of a combination of two lower layers may be conventionally applied.

In general, if the block refers to a thickness of 40mm or more, there is a problem that the manufacturing cost is too expensive to produce a block of this thickness only with artificial marble. For this reason, the upper part needs to be formed of artificial marble, and the lower part needs to be formed using ordinary cement concrete material.

Crushed aggregate, waste concrete aggregate, waste ascon aggregate, slag, etc. may be used as the aggregate of the lower layer, and the coarse aggregate maximum dimension is preferably 13 mm.

In order to make the block permeable, it is used to pass the crushed glass particles used in the upper layer by less than 10% in a 0.5 mm sieve, and the lower layer has a particle size range of the aggregate, the largest aggregate size is 13 mm, and 0.5 mm. It is desirable that the body passage and weight percentage be less than 10%.

On the other hand, if the block is to be impervious, the crushed glass particles used in the upper layer is used to pass more than 10% in the 0.5mm sieve, the lower layer is the aggregate size range of the aggregate, the coarse aggregate maximum dimension is 13mm It is preferable that the 0.5 mm barrel and the weight percentage should be 10% or more.

In forming the lower layer, 1 m 3 (approximately 1,500-2,000 kg) of aggregate having a maximum size of coarse aggregate is used in the range of 250-450 kg of cement and 60-180 kg of water. May be used, and cellulose, PP, PE, and the like, which are reinforcing fibers for cement, may be used.

The artificial marble block is formed by putting a mixture of these lower layer materials into a mold of a predetermined shape and vibrating, pressing or vibrating, and putting the above-described artificial marble mixture on the upper portion, vibrating, and pressing to combine the upper and lower layers. . Curing and final processing methods for the finished artificial marble is the same as in the production of the artificial marble panel seen earlier.

The present invention is a high temperature treatment of the indirect heating method to strengthen the bonding with the synthetic resin adhesive, so that the glass particles are not easily detached from the surface of the artificial marble, and also the manufacturing process in the artificial marble produced using the crushed glass To simplify the process, reduce the time required for manufacturing, and minimize manufacturing costs. Therefore, the present invention can obtain the effect of recycling resources by industrially using the waste glass, and on the other hand, by using a lot of inexpensive materials such as waste glass and cement, compared to other kinds of artificial marble products, significantly lower price It is very useful to provide artificial marble.

EMBODIMENT OF THE INVENTION Hereinafter, this invention is demonstrated based on an Example.

(Example 1)

This embodiment is 1,000 × 1,000 × 35 mm in size, the color of which is assumed to have black spots on the green, but was made to make artificial marble having a black ratio of about 30%.

100 kg of pulverized transparent glass passing 100% in a 4 mm sieve and 8% or less in a 0.5 mm sieve was put into an indirect heating mixer and heated to about 120 ° C. 70 kg of this was transferred to a secondary mixer, and 3 kg of epoxy resin and 1.2 kg of green pigment were added thereto and mixed with the heated ground glass, so that the surface of the ground glass particles was uniformly coated with epoxy and pigment. Then, 5 kg of silica sand with a particle size of 0.4-0.1 mm and 1.2 kg of cement were added thereto and mixed until the temperature reached room temperature. On the other hand, in order to manufacture a portion corresponding to black, 1.2 kg of epoxy resin, 0.6 kg of black pigment, 2 kg of silica sand of 0.4-0.1 mm particle size, and 0.5 kg of back cement were added to 30 kg of the heated glass. The same manufacturing method was applied.

18 kg of cement, 9 kg of water, 0.2 kg of water reducing agent as admixture, and 9 kg of aqueous epoxy were mixed in the green coating glass mixture (about 80 kg) and the black coating glass mixture (about 34 kg) prepared as described above.

The mixture was sprayed on a mold in which the bottom and sides of the steel plate 1,000 mm in length and width were separated from each other, and the mixture prepared above was introduced into the mold and vibrated and pressed to have a thickness of 35 mm. Then, the mold was moved to the curing room without removing the mold (a state in which the compaction was released), and the first curing was performed. After the mold was removed, the second curing was performed again. More than 5,000 cities were cured for sufficient curing in secondary curing. The surface of the cured artificial marble was polished using ceramic abrasive (No.100, No.200, No.400, No.800, No.1500, No.3000 as ceramic abrasive) Was sprinkled with polished wool to complete the final product, artificial marble.

The artificial marble manufactured by the above process was tested for tensile strength, flexural strength, compressive strength, Mohs hardness, and abrasion resistance. The test results are shown in Table 1 below.

Table 1

Test Items Tensile Strength (㎏ / ㎠) Flexural strength (㎏ / ㎠) Compressive strength (㎏ / ㎠) Mohs hardness Abrasion Resistance (mg) ASTM D4060 Test result 130 150 280 6.5 0.5 standard 30 or more 45 or more More than 200 5 or more 74 and below

As shown in the above table, the artificial marble of the present invention was not only excellent in tensile strength, bending strength, and compressive strength, but also excellent in hardness and wear resistance.

(Example 2)

In this embodiment, a 230 × 115 × 60 mm sized sidewalk block is fabricated. The upper artificial marble layer is 8 mm thick, and the lower cement concrete layer is 52 mm thick, water permeable, and the color is 70% red. Based on this, the white is mixed 30%, and after curing, the surface of artificial marble is polished to have a high gloss. The process of this embodiment is as follows.

1) Lower layer material manufacturing process: 1,700 kg of silica sand, 100 kg of cement, 380 kg of water, 35 kg of water and 0.25 kg of admixture (resining agent) were mixed by passing 100% through 5 mm sieve and 0.5% through 0.5 mm sieve to prepare the lower layer material. It was.

  2) Upper layer material manufacturing process: 200 kg of crushed glass passing 100% of 5 mm sieve and 3.0% of 0.5 mm sieve was indirectly heated to 130 ° C., and 8 kg of epoxy, 6 kg of 1.0-0.1 mm silica sand, 0.1 mm 16 kg of the silica sand powder and 2 kg of the red pigment were mixed until room temperature, thereby preparing a red coated glass mixture. And under the same conditions, but only white pigment to prepare a white coated glass mixture. Thus prepared red coating glass mixture 192 kg, white coating glass mixture 48 kg, 5 mm or less red color aggregate 60 kg, cement (white) 75 kg, pigment (red) 2.2 kg, water 18 kg, admixture (water absorber) 0.4 kg was mixed to make a top layer material.

  3) Forming process: The lower layer material is put into a mold of 230 × 115 × 70 mm and subjected to primary vibration and pressurization so as to have a thickness of 60 mm, and the upper layer material (to about 10 mm height) is put thereon, followed by vibration and It pressed and vibrated and pressed so that final total thickness might be 60 mm. Then, after removing the upper press plate, the primary steam curing for 10 hours or more, and then cured more than 5,000 cities (time × temperature) at room temperature.

4) Final processing process: After curing is completed, the surface of the upper layer is polished about 0.5 mm with ceramic abrasives (No.100, No.200, No.400, No.800, No.1500), and the cellum oxide is mixed again. After the polished fiber was sprinkled with high pressure, the final product was completed.

A quality test was performed on the artificial marble block manufactured as described above. The test results are as follows.

Item Flexural strength (㎏ / ㎠) Porosity (%) Permeability coefficient (cm / sec) color Glass Extrusion Rate (%) Abrasion Resistance (mg) (ASTM D4060) result 55 17.5 1.3 × 10-1 equivalence 92% 0.5 standard 50 or more 12 or more 1 × 10-2 Limit Sample 30 or more 74 and below

1 is a conceptual diagram showing a structure in which crushed glass particles and related materials are combined by the method of the present invention.

Claims (18)

Grinding the glass so as to form particles of 10 mm or less; Putting the pulverized glass of the electric process into an indirect heating mixer and heating to 100-200 ° C. to form micropores on the surface of the pulverized glass particles; Coating a surface of the glass particles by mixing one or two or more selected from epoxy, acrylic, or urethane with the glass particles of the electric process; Mixing at least one selected from silica sand, lime powder, limestone, gypsum and cement with coating glass particles of an electrical process of 1.0 mm or less; Mixing cement and water into the mixture of the electrical process; A step of molding the mixture of the above step into an artificial marble manufacturing mold; And    A method of manufacturing artificial marble comprising the step of curing the molded artificial marble of the electrical process. The method of claim 1, wherein at least one selected from the group consisting of epoxy, acryl, and urethane is mixed at 0.01-0.05 parts by weight based on 1 part by weight of the crushed glass. The method of claim 1, wherein one or two or more selected from silica sand, lime powder, limestone, gypsum and cement are mixed in an amount of 0.01 to 0.1 parts by weight based on 1 part by weight of the crushed glass. The artificial marble manufacturing method according to claim 1, wherein 0.1-0.3 parts by weight of electric cement and 0.02-0.1 parts by weight of electric water are mixed with respect to 1 part by weight of crushed glass. 5. The method of claim 4, wherein one or two or more selected from admixtures, pigments, reinforcing fibers, water-soluble resins, loess, charcoal, mica, silica, and color stones are mixed in a process immediately before the molding step. The method of claim 1, wherein the artificial marble is produced by spraying 30% or more of the coated glass particles by sprinkling on the surface of the molded artificial marble. The method of manufacturing a water-permeable artificial marble according to claim 1, wherein crushed glass which passes 100% in a 10 mm sieve and passes by less than 10% in a 0.5 mm sieve is used. The method of claim 1, wherein a crushed glass that passes 100% in a 10mm sieve and 10% or more in a 0.5mm sieve is used. Artificial marble prepared by the manufacturing method of claim 1 to claim 8. Coarse aggregate Aggregate 1m3 (approximately 1,500 ~ 2,000kg) of coarse aggregate is mixed with 250 ~ 450kg of cement and 60 ~ 180kg of water, and this mixture is put into the block manufacturing mold and the first vibration and pressure Forming a; The glass is pulverized to a particle size of 10 mm or less, and the crushed glass is placed in an indirect heating mixer and heated to 100-200 ° C. to form micropores on the surface of the pulverized glass particles. Mix one or two or more selected from epoxy, acrylic or urethane to coat the surface of the glass particles, and mix one or more selected from silica sand, lime, limestone, gypsum and cement with 1.0 mm or less of the coated glass particles. And mixing cement and water, and then putting the mixture on the upper portion of the lower layer formed by the electric process, vibrating and pressing to form the upper layer; And Process for curing the molded block of the electrical process; artificial marble block manufacturing method comprising a. The method of claim 10, wherein one or two or more selected from the epoxy, acryl or urethane is added in an amount of 0.01-0.05 parts by weight based on 1 part by weight of the crushed glass. 11. The method of claim 10, wherein the artificial marble block manufacturing method characterized in that the mixture of 0.01 to 0.1 parts by weight based on 1 part by weight of the crushed glass, or at least one selected from electro-silica sand, stone powder, limestone, gypsum, cement. The method of claim 10, wherein 0.1-0.3 parts by weight of electric cement and 0.02-0.1 parts by weight of electric water are mixed with respect to 1 part by weight of crushed glass. 15. The method of claim 13, wherein at least one selected from admixtures, pigments, reinforcing fibers, water-soluble resins, loess, charcoal, mica, silica, and color stones is mixed in a process immediately before the molding step. . The method of claim 10, wherein the artificial marble block manufacturing method characterized in that the sputtered on the surface of the molded artificial marble is protruded after at least 30% of the coated glass particles. The use of crushed glass according to claim 10, which uses 100% of passage in a 10 mm sieve and less than 10% in a 0.5 mm sieve, and uses aggregates having a maximum aggregate size of 13 mm and passing less than 10% in a 0.5 mm sieve. Water-permeable artificial marble block manufacturing method characterized in that The use of crushed glass which passes 100% in a 10 mm sieve and passes 10% or more in a 0.5 mm sieve, and uses aggregates having a maximum aggregate size of 13 mm and passing 10% or more in a 0.5 mm sieve. Non-permeable artificial marble block manufacturing method characterized in that Artificial marble block produced by the manufacturing method of claim 10.

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