KR20170014647A - Resin composition for engineered stone and engineered stone produced therefrom - Google Patents

Abstract

The resin composition for engineered stone of the present invention comprises a matrix resin; An inorganic aggregate having a Mohs hardness of more than 3 and not more than 9; And a mineral having an average particle diameter of 1 to 50 μm and a Mohs hardness of 1 to 3. The engineered stone formed from the engineered stone resin composition is excellent in crack resistance, scratch resistance, workability, color and the like.

Description

TECHNICAL FIELD [0001] The present invention relates to a resin composition for engineered stones, and a resin composition formed from the resin composition for engineered stones,

The present invention relates to an engineered stone resin composition and engineered stone formed therefrom. More specifically, the present invention relates to a resin composition for engineered stones excellent in crack resistance, scratch resistance, workability, color, and engineered stones formed therefrom.

Natural stones such as granite and marble have been used as decorative materials since ancient times because of their beautiful surface patterns. Natural stone is a material showing high-quality texture, and its demand has been greatly increased in the fields of flooring, wall, and sink top plate. However, since expensive natural stone can not meet the demand, various kinds of artificial stones are being developed.

Among such artificial stones, engineered stone (resin-reinforced natural stone) is a resin composition obtained by mixing a natural mineral and a binder resin under compression or vibration or under vacuum / vibration conditions, thereby showing the texture of natural stone. Engineered stones may be prepared to have a multicolor tone by being produced in a single color, or by blending a resin mixture with each of the pigments of different colors added thereto in a mixer, or using a chip to have a natural stone texture. In addition, engineered stones can be manufactured to exhibit various colors and textures according to mixed natural minerals, kinds of binder resins, color of pigment, agitation process, etc., and natural stone texture can be better represented because natural mineral is used as main material .

However, engineered stones which use natural minerals as their main raw materials have a problem that cracks are frequently generated during processing (cutting) due to too high hardness. Until now, methods to improve cutting conditions such as saw blade used for cutting and cutting speed have been used rather than controlling the physical properties of the product, but this is not a fundamental solution.

Therefore, there is a need to develop a resin composition for engineered stones and engineered stones capable of improving crack resistance and workability without deteriorating color and other physical properties.

An object of the present invention is to provide a resin composition for engineered stones capable of realizing excellent crack resistance, scratch resistance, workability, color and the like.

Another object of the present invention is to provide an engineered stone formed from the resin composition for engineering stone excellent in crack resistance, scratch resistance, workability, color and the like.

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

One aspect of the present invention relates to a resin composition for engineered stones. The resin composition comprises a matrix resin; An inorganic aggregate having a Mohs hardness of more than 3 and not more than 9; And a mineral having an average particle diameter of 1 to 50 μm and a Mohs hardness of 1 to 3.

In an embodiment, the resin composition comprises 5 to 20% by weight of the matrix resin; 40 to 94% by weight of the inorganic aggregate; And 1 to 10% by weight of the mineral.

In an embodiment, the weight ratio of the matrix resin and the inorganic aggregate may be 1: 1 to 1:30.

In an embodiment, the weight ratio of the mineral and the inorganic aggregate may be from 1: 5 to 1:60.

In a specific example, the matrix resin may include at least one of a polyester resin, an acrylic resin, an epoxy resin, and a polyurethane resin.

In an embodiment, the matrix resin may be an unsaturated polyester resin.

In an embodiment, the inorganic aggregate may be a silica-based natural mineral.

In an embodiment, the inorganic aggregate may include at least one of a silica sand, a quartz chip, and a silica powder.

In an embodiment, the inorganic aggregate may comprise 20 to 75 wt% of a silica sand, 0.1 to 40 wt% of a quartz chip, and 20 to 40 wt% of a silica powder.

In an embodiment, the mineral may comprise at least one of talc (talc), gypsum and calcite.

In an embodiment, the resin composition may further include at least one of a curing agent, a curing accelerator, a silane coupling agent, and a pigment.

In embodiments, the resin composition may have a cut load of less than 8 A (amperes) measured at a speed of 2 m / min using a cutter, for a compression molded specimen of 20 mm thickness.

Another aspect of the present invention relates to engineered stones formed from the resin composition for Engineered Stone.

The present invention relates to a resin composition for engineered stone capable of realizing excellent crack resistance, scratch resistance, workability, color and the like and an engineered stone excellent in crack resistance, scratch resistance, workability and color formed therefrom Effect.

Hereinafter, the present invention will be described in detail.

The resin composition for engineered stone according to the present invention comprises (A) a matrix resin; (B) an inorganic aggregate having a Mohs hardness of more than 3 and not more than 9; And (C) a mineral having a Mohs hardness of 1 to 3.

(A) Matrix resin

As the matrix resin, a matrix resin used for engineering stones (resin-reinforced natural stone) known in the art can be used without limitation. For example, an (unsaturated) polyester resin, an acrylic resin, an epoxy resin, a polyurethane resin, a combination thereof, or the like can be used. Specifically, an unsaturated polyester resin or an acrylic resin can be used.

In an embodiment, the (unsaturated) polyester resin may be prepared by condensation reaction of an alpha, beta -unsaturated dibasic acid or a mixture of the dibasic acid and a saturated dibasic acid with a polyhydric alcohol. For example, the polyester resin may be prepared by mixing the dibasic acid or the like with a polyhydric alcohol in a specific ratio (for example, alcoholic hydroxyl group moles / carboxyl group moles = 0.8 to 1.2) The mixture is condensed at a temperature of from 140 to 250 ° C under a gas stream to remove the produced water and gradually raise the temperature according to the progress of the reaction, but the present invention is not limited thereto.

Examples of the?,? - unsaturated dibasic acids and saturated dibasic acids include maleic anhydride, citraconic acid, fumaric acid, itaconic acid, phthalic acid, , Phthalic anhydride, isophthalic acid, terephthalic acid, succinic acid, aipic acid, sebacic acid, tetrahydrophthalic acid, and combinations thereof. And polyhydric alcohols such as ethylene glycol, diethylene glycol, triethylene glycol, propylene glycol, dipropylene glycol, tripropylene glycol, polypropylene glycol, 1,3-butylene glycol, hydrogenated bisphenol-A, neopentyl glycol, 2,2,4-trimethyl-1,3-pentanediol, glycerin, combinations of these, and the like. The polyester resin may be a monobasic acid such as acrylic acid, propionic acid or benzoic acid; Or a polybasic acid such as trimellitic acid, tetracarboxylic acid of benzol, and the like.

In an embodiment, the polyester resin may have a weight average molecular weight measured by gel permeation chromatography (GPC) of 1,000 to 10,000 g / mol, for example 1,500 to 4,000 g / mol. Within the above range, the resin composition for engineered stone can have excellent processability and the like.

In an embodiment, the acrylic resin is a polymer of a (meth) acrylic monomer such as methyl (meth) acrylate, ethyl (meth) acrylate, butyl (meth) acrylate, 2-ethylhexyl But are not limited to, polymers of monomers (blends), including but not limited to, benzyl (meth) acrylate, glycidyl (meth) acrylate, combinations thereof and the like.

In an embodiment, the acrylic resin may have a weight average molecular weight measured by gel permeation chromatography (GPC) of 10,000 to 150,000 g / mol, for example, 30,000 to 100,000 g / mol. Within the above range, the resin composition for engineered stone can have excellent processability and the like.

As the epoxy resin, bisphenol-A type epoxy resin, bisphenol-S type epoxy resin, tetraphenyl ethane epoxy resin, phenol novolak type epoxy resin, a mixture thereof and the like can be used, but the present invention is not limited thereto.

In an embodiment, the matrix resin may comprise 5 to 20% by weight, for example 6 to 13% by weight, of 100% by weight of the total resin composition. Within the above range, the engineered stone resin composition can be excellent in fluidity and the like, and an engineered stone excellent in workability, appearance (color, etc.) can be obtained.

(B) Inorganic aggregate

The inorganic aggregate is capable of exhibiting the appearance and texture of natural stone, and inorganic aggregates used in known engineering stone (resin-reinforced natural stone) can be used without limitation.

In an embodiment, the inorganic aggregate has a Mohs hardness of not less than 9 and not more than 9, for example, 6 to 8, and is a natural mineral having transparency. Examples of the natural mineral include silica-based natural minerals such as silica sand, quartz chips quartz chips, silica powders, combinations thereof, and the like. When the Mohs hardness of the inorganic aggregate is less than 3, the surface hardness of the engineered stone may be lowered. If the Moh hardness exceeds 9, the processability and crack resistance of the engineered stone may be lowered.

In an embodiment, the inorganic aggregate contains 20 to 75 wt%, for example, 30 to 65 wt% of the silica sand, 0.1 to 40 wt% of the quartz chip, for example, 7 to 35 wt% % Of the silica powder, and 20 to 40 wt%, for example, 22 to 35 wt% of the silica powder. It is possible to obtain a resin composition for engineered stone capable of realizing the appearance and texture closer to natural stone in the above range.

In an embodiment, the silica sand may have an average particle size as measured by a sieving method (apparatus) of 0.1 to 1.5 mm, such as 0.1 to 1.2 mm, and the quartz chip has an average particle size mm, for example, 1.3 to 9 mm, and the silica powder may have an average particle diameter of 5 to 50 mu m, for example, 10 to 45 mu m. It is possible to obtain a resin composition for engineered stone which can be easily mixed with the matrix resin in the above range, can prevent the occurrence of pores when mixed with the matrix resin, and can realize appearance and texture close to natural stone.

In an embodiment, the inorganic aggregate may be contained in an amount of 40 to 95% by weight, for example, 75 to 90% by weight, specifically 80 to 90% by weight, based on 100% by weight of the total resin composition. Within the above range, the engineered stone resin composition can be excellent in fluidity and the like, and an engineered stone excellent in workability, appearance (color, etc.) can be obtained.

In a specific example, the weight ratio (A) :( B) of the matrix resin (A) and the inorganic aggregate (B) is from 1: 1 to 1:30, for example, from 1: 6 to 1:15, 1: 7 to 1:14. It is possible to obtain an engineered stone having better processability, appearance characteristics and the like in the above range.

(C) Minerals

The mineral may improve the anti-cracking property of the engineered stone, and it may have a Mohs hardness of 1 to 3 and an average particle size measured by a particle size analyzer of 1 to 50 μm, for example, 5 to 45 μm. When the Mohs hardness of the mineral is less than 1, the surface hardness of the engineered stone may be lowered. When the Mohs hardness exceeds 3, the crack resistance of the engineered stone may not be improved. If the average particle diameter of the mineral is less than 1 탆, the mineral may not be uniformly dispersed in the resin composition. If the average particle diameter exceeds 50 탆, the crack resistance of the engineered stone may not be improved.

In an embodiment, the mineral may be talc (talc), gypsum, calcite, combinations thereof, and the like, preferably talc (talc).

In an embodiment, the mineral may comprise 1 to 10 wt%, for example 2 to 5 wt%, of 100 wt% of the total resin composition. In the above range, engineered stone having improved workability, appearance (color, etc.), mechanical properties, and the like can be obtained in comparison with conventional engineered stones.

In a specific example, the weight ratio ((C) :( B)) of the mineral (C) and the inorganic aggregate (B) is from 1: 5 to 1:60, for example, from 1: 7 to 1:50, : 10 to 1:45. In this range, engineered stones having better crack resistance, scratch resistance, workability, appearance, and balance of physical properties can be obtained.

The resin composition for Engineered Stone according to one embodiment of the present invention may further include additives including a curing agent, a curing accelerator, a silane coupling agent, a pigment, a combination of these, and the like.

As the additive, additives known in the resin composition for engineering stone (resin-based natural reinforcing stone composition) can be used without limitation. For example, the curing agent may be t-butyl peroxy benzoate (TBPB), methyl ethyl ketone peroxide (MEKPO) or a combination thereof. As the pigment, a reddish brown pigment such as iron oxide, a yellow pigment such as iron hydroxide, a green pigment such as chromium oxide, an azure blue pigment such as sodium aluminosilicate, a white pigment such as titanium oxide, Pigments, black pigments such as carbon black, azo pigments, phthalocyanine pigments, etc., and pearl can be further added and used, but the present invention is not limited thereto.

When the additive is used, it is not particularly limited as long as it does not deteriorate the physical properties of the present invention. For example, the additive may be included in an amount of 0.1 to 30 parts by weight per 100 parts by weight of the matrix resin.

In the resin composition for engineered stone according to one embodiment of the present invention, the compression molded specimen having a thickness of 20 mm is measured at a speed of 2 m / min using a cutting machine (manufactured by Prime Engineering Co., Ltd.) A cutting load of 8 A (ampere) or less, for example 7 to 8 A. It is possible to reduce the generation of cracks during engineered stone cutting in the above range, and the workability can be excellent.

The engineered stone according to the present invention is formed from the resin composition for engineered stone. For example, the resin composition may be prepared (molded) according to a known engineering stone manufacturing method using the resin composition. Specifically, the respective components of the resin composition may be mixed (agitated), compression molded and cured under vibration or vacuum / vibration conditions, and then, if necessary, surface polished. Since such a process is well known, a detailed description thereof will be omitted.

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.

Example

Example  One: Engineer Stone's  Produce

(Trade name: ATM100) having a weight average molecular weight of 2,500 g / mol (trade name: ATM100) as the matrix resin (A) and an inorganic aggregate (B1) (Manufactured by Kale Maden, average particle diameter: 0.1 to 1.2 mm), (B2) quartz chips (manufactured by 21st century silica, average particle diameter: 1.2 to 9 mm) and (B3) silica powder (Manufactured by KOCH, average particle diameter: 1 to 45 mu m) as a mineral having a Mohs hardness of 1 to 3, and a curing agent (an average particle diameter: 10 to 45 mu m) 1 to 3 parts by weight of tributyl peroxybenzoate (TBPB), manufactured by Century Akema), 0.1 to 0.3 parts by weight of a curing accelerator (6% cobalt-octoate, manufactured by Jinyang Chemical Industry Co., Ltd.) , product name: of HUNTSMAN TR92) 1 to 5: WD-70) 1 to 3 parts by weight of pigment (TiO _2, Manufacturer: Woosin pigment, product Additional parts and mixed to obtain a resin composition. Next, the resin composition was put into a mold having a size of 600 mm * 600 mm * 100 mm, and the mold was vibrated for 2 minutes by up-and-down vibration at a motor speed of 3,600 rpm, and then a pressure of 2 to 3 bar, Compression molded under vacuum conditions, and the resin was cured at 90 DEG C for 1 hour to prepare an engineered stone. The cutting load of the manufactured engineered stone was measured and is shown in Table 1 below.

Example  2: Engineer Stone's  Produce

An engineered stone was prepared in the same manner as in Example 1 except that the contents of the inorganic aggregate (B) and the mineral (C) were different according to the composition and content of the following Table 1. The cutting load of the manufactured engineered stone was measured and is shown in Table 1 below.

Comparative Example  One: Engineer Stone's  Produce

An engineered stone was prepared in the same manner as in Example 1 except that calcium carbonate (Moh's hardness: 3.5) was used instead of the talc (mineral (C)). The cutting load of the manufactured engineered stone was measured and is shown in Table 1 below.

Comparative Example  2: Engineer Stone's  Produce

An engineered stone was prepared in the same manner as in Example 1 except that alumina hydrate (ATH, Moh's hardness: 4 to 5) was used instead of the talc (mineral (C)). The cutting load of the manufactured engineered stone was measured and is shown in Table 1 below.

Property evaluation method

(1) Cutting load (unit: A (ampere)): The cut load was measured at a cutting speed of 2 m / min using a cutter (Prime Engineering Co., Ltd.) .

(2) Evaluation of scratch resistance: After polishing the surface of a specimen with a grinding stone of # 50 to # 2500 for 3 minutes using a grinder (manufacturer: Sung Chang Machinery Co., Ltd.), whether or not scratches were generated on the surface of the specimen Respectively. If more than one scratch was found, nonconformity and no scratches were evaluated.

Example 1 Example 2 Comparative Example 1 Comparative Example 2 (A) (% by weight) 10 10 10 10 (B) (% by weight) (B1) 50 50 50 50 (B2) 13 13 13 13 (B3) 22 25 22 22 (C) Talc (% by weight) 5 2 - - Calcium carbonate (% by weight) - - 5 - Aluminum hydroxide (% by weight) - - - 5 Cut load (A) 7.5 7.9 8.5 8.5 Scratch resistance fitness fitness incongruity incongruity

From the above results, the resin composition for engineered stone of the present invention (Examples 1 and 2) contains minerals having a Mohs hardness of 1 to 3, and the cutting load was 7.9 A or less, thereby improving the crack resistance and workability of Engineered Stone And scratch resistance and the like are excellent.

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

Claims (13)

Matrix resin;
An inorganic aggregate having a Mohs hardness of more than 3 and not more than 9; And
And a mineral having an average particle diameter of 1 to 50 占 퐉 and a Mohs hardness of 1 to 3. The resin composition for engineered stone according to claim 1,
The resin composition according to claim 1, wherein the resin composition comprises 5 to 20% by weight of the matrix resin; 40 to 94% by weight of the inorganic aggregate; And 1 to 10% by weight of the above-mentioned minerals.
The resin composition for engineered stone according to claim 1, wherein the weight ratio of the matrix resin and the inorganic aggregate is 1: 1 to 1:30.
The resin composition for engineered stone according to claim 1, wherein the weight ratio of the mineral and the inorganic aggregate is 1: 5 to 1:60.
The resin composition for engineered stones according to claim 1, wherein the matrix resin comprises at least one of a polyester resin, an acrylic resin, an epoxy resin, and a polyurethane resin.
The resin composition for engineered stones according to claim 1, wherein the matrix resin is an unsaturated polyester resin.
The resin composition for engineered stone according to claim 1, wherein the inorganic aggregate is a silica-based natural mineral.
The resin composition for engineered stone according to claim 1, wherein the inorganic aggregate contains at least one of silica sand, quartz chips, and silica powder.
The resin composition for engineered stone according to claim 1, wherein the inorganic aggregate comprises 20 to 75% by weight of a silica sand, 0.1 to 40% by weight of a quartz chip, and 20 to 40% by weight of a silica powder.
The resin composition for engineered stone according to claim 1, wherein the mineral comprises at least one of talc, gypsum and calcite.
The resin composition for engineered stones according to claim 1, wherein the resin composition further comprises at least one of a curing agent, a curing accelerator, a silane coupling agent and a pigment.
The resin composition for engineered stones according to claim 1, wherein the resin composition has a cut load of 8 A (amperes) or less measured at a speed of 2 m / min using a cutter with respect to a compression molded specimen having a thickness of 20 mm Composition.
An engineered stone formed from the resin composition for engineered stone according to any one of claims 1 to 12.