KR20180041543A - Artificial marble and method for preparing the same - Google Patents

Abstract

Artificial marble of the present invention includes a resin layer, and a glass fiber veil layer having the thickness of 100 to 200 μm and impregnating the inside of the resin layer. The artificial marble has excellent bending strength and can be thermoformed.

Description

[0001] ARTIFICIAL MARBLE AND METHOD FOR PREPARING THE SAME [0002]

The present invention relates to artificial marble and a method for producing the same. More particularly, the present invention relates to an artificial marble having excellent tensile strength, bending strength and the like and capable of thermoforming, and a method for producing the same.

Artificial marble such as acrylic artificial marble is widely used because it has the same texture as natural stone. Generally, acrylic artificial marble is prepared by curing an artificial marble composition to which aluminum hydroxide, silica, quartz and the like as an inorganic filler and a peroxide initiator as an initiator are added to a syrup obtained by dissolving polymethyl methacrylate in a methyl methacrylate monomer, In the form of a continuous process.

However, existing acrylic artificial marble has a problem in that its shape may be deformed during curing, and it is difficult to manufacture the artificial marble in a thin thickness due to problems such as breakage during processing. In order to reduce the occurrence of cracks in the artificial marble or to improve the bending strength and the like, a glass fiber reinforcing agent having a form such as a chopped strand mat, a yarn cloth, a roving cloth, It is difficult to impregnate the resin in a short period of time because the thickness of the glass fiber reinforcing agent is large and the glass fiber is exposed to the processed surface or the cut surface at the time of processing the artificial marble,

Therefore, it is necessary to develop an artificial marble which is excellent in tensile strength, bending strength, etc., and which can be manufactured to a thin thickness and can be thermoformed, without deterioration in curing, breakage in processing, and appearance.

The background art of the present invention is disclosed in Korean Patent Publication No. 2015-0030401.

An object of the present invention is to provide an artificial marble excellent in tensile strength, bending strength and the like and capable of thermoforming, and a method for producing the same.

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

One aspect of the invention relates to artificial marble. The artificial marble comprises a resin layer; And a glass fiber veil layer having a thickness of 100 to 200 mu m impregnated in the inside of the resin layer.

In an embodiment, the resin layer may include a matrix resin including at least one of an acrylic resin, an epoxy resin, and a polyurethane resin.

In an embodiment, the artificial marble comprises 250 parts by weight of inorganic filler comprising at least one of silica, alumina, calcium carbonate, calcium hydroxide, aluminum hydroxide, magnesium hydroxide, pearlite, vermiculite, smectite and bentonite with respect to 100 parts by weight of the matrix resin Or more.

In an embodiment, the inorganic filler may be dispersed in the resin layer and the glass fiber bale layer.

In an embodiment, the artificial marble may further include at least one of a crosslinking agent, a crosslinking accelerator, a defoaming agent, a dispersing agent, a coupling agent and a pigment.

In an embodiment, the artificial marble may have a thickness of 2 to 4 mm.

In an embodiment, the artificial marble may have a flexural strength of 60 to 65 MPa of a 3 mm thick specimen measured according to ASTM D790.

Another aspect of the present invention relates to a method of manufacturing the artificial marble. The method comprises: firstly applying a resin composition for forming a resin layer on a release film; A glass fiber veil having a thickness of 100 to 200 占 퐉 is laid over the applied resin composition; Secondarily applying the resin composition to the upper portion of the glass fiber bale so that the glass fiber veil is impregnated; And curing the resin composition.

In an embodiment, the resin composition may include a resin syrup containing at least one of an acrylic resin syrup, an epoxy resin syrup, and a polyurethane resin syrup.

In an embodiment, the resin composition is an inorganic filler comprising 250 parts by weight of an inorganic filler containing at least one of silica, alumina, calcium carbonate, calcium hydroxide, aluminum hydroxide, magnesium hydroxide, pearlite, vermiculite, smectite and bentonite, Or more.

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

In an embodiment, the thickness of the first coated resin composition may be 2 to 3 mm, and the thickness of the second coated resin composition may be 2 to 3 mm.

In an embodiment, the artificial marble may have a thickness of 2 to 4 mm.

In embodiments, the curing may be performed at 40 to 60 < 0 > C.

INDUSTRIAL APPLICABILITY The present invention has an effect of providing artificial marble having excellent tensile strength, bending strength and the like and capable of thermoforming and a method for producing the same.

1 is a schematic cross-sectional view of an artificial marble according to an embodiment of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will now be described in detail with reference to the accompanying drawings. However, the techniques disclosed in the present invention are not limited to the embodiments described herein but may be embodied in other forms. It should be understood, however, that the embodiments disclosed herein are provided so that this disclosure will be thorough and complete, and will fully convey the concept of the invention to those skilled in the art. In the drawings, the width, thickness, and the like of the components are slightly enlarged in order to clearly illustrate the components. In addition, although only a part of the components is shown for convenience of explanation, those skilled in the art can easily grasp the rest of the components. It is to be understood that when an element is described as being located at the top or bottom of another element, it is to be understood that the element may be located directly above or below another element, or where additional elements may be interposed between elements Quot; upper "and" lower "are based on the drawings. It will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the spirit and scope of the invention. Also, the singular " include "should be understood to include plural representations unless the context clearly dictates otherwise, and the terms" comprises, " It should be understood that they are intended to specify the presence of a combination of both, and do not preclude the presence or addition of one or more other features, numbers, steps, operations, components, or combinations thereof.

1 is a schematic cross-sectional view of an artificial marble according to an embodiment of the present invention. As shown in FIG. 1, the artificial marble 100 of the present invention comprises a resin layer 10; And a glass fiber veil layer (20) impregnated inside the resin layer (10).

In an embodiment, the resin layer 10 may include a matrix resin used in a known artificial marble, and may include, for example, an acrylic resin, an epoxy resin, a polyurethane resin, a combination thereof, and the like.

The acrylic resin is not particularly limited and includes, for example, methyl (meth) acrylate, ethyl (meth) acrylate, butyl (meth) acrylate, 2-ethylhexyl (meth) A polymer of an acrylic monomer such as glycidyl (meth) acrylate or a mixture thereof, or a resin syrup obtained by dissolving a polymer of the acrylic monomer in the acrylic monomer. The acrylic resin may have a weight average molecular weight measured by gel permeation chromatography (GPC) after curing of 80,000 to 111,000 g / mol, for example, 88,000 to 90,000 g / mol. Particularly, when the acrylic resin is used in artificial marble, it can exhibit both thermoplastic and thermosetting properties and is useful for flexible thermoforming.

The epoxy resin is not particularly limited, and for example, a bisphenol A epoxy resin, a bisphenol S epoxy resin, a tetraphenyl ethane epoxy resin, a phenol novolak type epoxy resin, a mixture thereof and the like can be used.

In an embodiment, the glass fiber bale layer 20 is formed by impregnating a glass fiber veil having a thickness of 100 to 200 mu m, for example, 110 to 140 mu m in thickness, into the resin layer 10, The tensile strength, the bending strength, and the like of the marble 100 can be improved. Thus, the artificial marble 100 can be made thin and thermoformed. When the thickness of the glass fiber bale is less than 100 탆, the effect of improving the physical properties such as tensile strength and bending strength of the artificial marble may be deteriorated. When the thickness exceeds 200 탆, it is difficult to impregnate the resin, Artificial marble having a thickness may not be manufactured.

In the present specification, the glass fiber veil means a sheet obtained by bonding one strand of glass fiber, and a chopped strand mat is a sheet obtained by bonding a plurality of strands of glass fiber on the basis of weight per unit meter, A yarn cloth or a roving cloth is formed into a sheet form by assembling a plurality of strands of glass fiber in a woven form, and can be classified according to the weight of the glass fiber strand and the weight per unit of weight.

In the specific example, the artificial marble 100 is prepared by adding silica, alumina, calcium carbonate, calcium hydroxide, hydroxides or the like to the resin layer 10 in order to improve surface strength, flame retardancy, Aluminum, magnesium hydroxide, pearlite, vermiculite, smectite, bentonite, combinations thereof, and the like. For example, in the case of acrylic artificial marble, calcium hydroxide, aluminum hydroxide and the like can be mainly used.

In an embodiment, the inorganic filler may be particulate and may have an average particle size of 1 to 6 mm, a specific gravity of 0.1 to 3, such as an average particle size of 10 to 4 mm, and a specific gravity of 0.5 to 2.6. In the above range, the appearance characteristics, texture, surface strength and the like of the artificial marble can be excellent. The inorganic filler may be contained in an amount of 250 parts by weight or less, for example, 0.1 to 250 parts by weight, and more preferably 50 to 200 parts by weight, based on 100 parts by weight of the matrix resin. In the above range, the appearance characteristics, texture, surface strength, flame retardancy and the like of the artificial marble can be excellent.

The artificial marble 100 according to one embodiment of the present invention may further include at least one of a crosslinking agent, a crosslinking accelerator, an antifoaming agent, a dispersing agent, a coupling agent and a pigment, if necessary. As the additive, known additives used in artificial marble can be used without limitation.

As the crosslinking agent, a compound having a double bond in the molecule capable of crosslinking with the matrix resin may be used without limitation. (Meth) acrylate (EDMA), diethylene glycol di (meth) acrylate (2EDMA), triethylene glycol di (meth) acrylate (3EDMA), tetraethylene glycol di (Meth) acrylate, neopentyl glycol di (meth) acrylate, tetraethylene glycol di (meth) acrylate, trimethylolpropane tri (meth) acrylate, A mixture thereof, and the like can be used.

The crosslinking accelerator promotes polymerization and curing reaction of the resin composition in the process of producing artificial marble. Examples of the crosslinking accelerator include diacyl peroxide such as benzoyl peroxide and dicumyl peroxide; Hydroperoxides such as butyl hydroperoxide, t-butyl hydroperoxide and cumyl hydroperoxide; t-butyl peroxymaleic acid, t-butyl peroxymaleate; t-butyl hydroperoxybutyrate; Acetyl peroxide; Lauroyl peroxide; Azobisisobutyronitrile; Azobisdimethylvaleronitrile; t-butyl peroxyethyl hexanoate; t-butyl peroxyneodecanoate; amyl peroxy-2-ethyl hexanoate, and the like, but not limited thereto.

In an embodiment, the artificial marble 100 may have a thickness of 2 to 4 mm, for example 2.5 to 3.5 mm. In the above range, the artificial marble may have excellent tensile strength, bending strength, etc., and may be thermoformed. The artificial marble 100 may have a thickness ratio (upper: lower) of 4: 6 to 6: 4 between the upper resin layer 10a and the lower resin layer 10b of the glass fiber bale layer 20. In the above range, the artificial marble may have excellent tensile strength, bending strength, etc., and may be thermoformed.

The artificial marble according to one embodiment of the present invention is formed by firstly applying a resin composition for forming a resin layer on a release film such as a PVA film; Laying the glass fiber veil on top of the applied resin composition; Secondarily applying the resin composition to the upper portion of the glass fiber bale so that the glass fiber veil is impregnated; And then curing the resin composition.

In an embodiment, the resin composition may include at least one of an acrylic resin syrup, an epoxy resin syrup, and a polyurethane resin syrup.

In an embodiment, the resin composition may further include an inorganic filler and / or one or more additives selected from a crosslinking agent, a crosslinking accelerator, a defoaming agent, a dispersing agent, a coupling agent and a pigment. For example, the content of the inorganic filler may be 250 parts by weight or less, for example, 0.1 to 250 parts by weight, and more preferably 50 to 200 parts by weight, based on 100 parts by weight of the resin syrup (matrix resin). The content of the crosslinking agent and the crosslinking accelerator may be 0.1 to 5 parts by weight, for example, 0.2 to 3.0 parts by weight based on 100 parts by weight of the resin syrup (matrix resin). Within this range, the resin layer can be sufficiently cured. The content of the additive excluding the crosslinking agent and the crosslinking accelerator may be 10 parts by weight or less, for example, 0.01 to 5 parts by weight, based on 100 parts by weight of the resin syrup.

In an embodiment, the thickness of the first coated resin composition may be 2 to 3 mm, and the thickness of the second coated resin composition may be 2 to 3 mm. In this range, the thickness ratio (upper: lower) of the upper resin layer 10 and the lower resin layer 10 of the glass fiber bale layer 20 can be 4: 6 to 6: 4, Strength, flexural strength and the like can be excellent, and thermoforming and the like can be possible.

In an embodiment, the curing of the resin composition may be carried out according to a known curing method in the manufacture of artificial marble. For example, after the second application of the resin composition, the total thickness may be adjusted to 4 to 6 mm and then cured at a temperature of 80 to 120 ° C for 1 hour or more.

The artificial marble according to one embodiment of the present invention may have a flexural strength of 60 to 65 MPa, for example 62 to 64 MPa, of 3 mm thick specimen measured according to ASTM D790.

In an embodiment, the artificial marble may be thermoformable by bending at a temperature of 130 ° C to 180 ° C for one hour.

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 1: Preparation of artificial marble

100 parts by weight of a syrup prepared by dissolving 18% by weight of polymethylmethacrylate (PMMA) in 82% by weight of methyl methacrylate, 180 parts by weight of silica powder and 0.5 part by weight of calcium hydroxide as an inorganic filler, 0.5 part by weight of trimethylolpropane tri 0.7 parts by weight of methacrylate, 2.0 parts by weight of a mixture of t-butyl peroxymaleate and t-butyl peroxyethyl hexanoate as a crosslinking accelerator (initiator), 0.5 part by weight of n-dodecyl mercaptan as a chain transfer agent, 0.4 and 0.1 part by weight of the antifoaming agent and 0.5 part by weight of the dispersing agent and 0.5 part by weight of the silane coupling agent were thoroughly agitated and then vacuum-defoamed and applied to the PVA film (release film) first to a thickness of 2 mm. 140 占 퐉 glass fiber veil was applied, the resin composition was applied in a second thickness of 2 mm and then cured at a temperature of 80 占 폚 to prepare artificial marble, The longitudinal thickness was adjusted to be 3 mm.

Comparative Example 1: Production of artificial marble

Artificial marble was prepared in the same manner as in Example 1, except that a glass fiber veil was not applied and the resin composition was applied to produce artificial marble and then both sides were processed to give a final thickness of 5 mm.

Comparative Example 2: Production of artificial marble

Except that a glass fiber reinforcing agent in the form of a chopped strand mat having a thickness of 700 to 800 탆 was used instead of the glass fiber bale to obtain a final thickness of 5 mm, Marble was produced.

Comparative Example 3: Production of artificial marble

The procedure of Example 1 was repeated except that a glass fiber reinforcing agent in the form of a yarn cloth having a thickness of 500 to 600 탆 was used instead of the glass fiber bale to obtain a final thickness of 5 mm. .

Comparative Example 4: Production of artificial marble

Artificial marble was prepared in the same manner as in Example 1, except that the glass fiber veil was not applied and the resin composition was applied to have a total thickness of 13 mm.

Property evaluation method

(1) Flexural Strength (Unit: MPa): Flexural strengths of specimens having respective thicknesses after curing were measured in accordance with ASTM D790.

(2) Thermoforming evaluation: Each of the artificial marble prepared in Example 1 and Comparative Examples 1 to 4 was placed in a mold of a stainless steel material manufactured by fixing a semicircular pipe having a radius of 25 mm to a plate, Heated at 180 [deg.] C, and then the heated artificial marble was held in close contact with the mold. After cooling to room temperature (about 25 ° C), the occurrence of cracks in the warped portion of the artificial marble was observed to determine whether or not thermoformability was possible (o: occurrence of cracks, x: occurrence of cracks).

Example 1 Comparative Example 1 Comparative Example 2 Comparative Example 3 Comparative Example 4 Resin syrup 100 100 100 100 100 Inorganic filler 180.5 180.5 180.5 180.5 180.5 Fiberglass veil use - - - - Strut mat - - use - - Yank Cross - - - use - Final thickness 3 mm 5 mm 5 mm 5 mm 12 mm Flexural strength 63 45 40 84 60 Thermoforming ○ ○ × × ×

From the above results, it can be seen that the artificial marble of the present invention (Example 1) has excellent bending strength and tensile strength and is thermoformable.

On the other hand, in the case of Comparative Example 1 in which the glass fiber veil was not applied, it was found that the bending strength was lowered. In the case of Comparative Example 2 in which the glass strand mat was used instead of the glass fiber veil, the bending strength was decreased and the thermoforming was impossible In Comparative Example 3 using a yarn cloth instead of a glass fiber veil and Comparative Example 4 in which a final thickness of the artificial marble was made thick to 12 mm without applying a glass fiber veil, excessive cracks were generated, This is not possible.

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 (14)

Resin layer; And
And a layer of a glass fiber veil having a thickness of 100 to 200 탆 impregnated inside the resin layer.
The artificial marble according to claim 1, wherein the resin layer comprises a matrix resin comprising at least one of an acrylic resin, an epoxy resin and a polyurethane resin.
The artificial marble according to claim 2, wherein the artificial marble is an inorganic filler comprising at least one of silica, alumina, calcium carbonate, calcium hydroxide, aluminum hydroxide, magnesium hydroxide, pearlite, vermiculite, smectite and bentonite with respect to 100 parts by weight of the matrix resin 250 parts by weight or less.
The artificial marble according to claim 3, wherein the inorganic filler is dispersed in the resin layer and the glass fiber bale layer.
The artificial marble according to claim 1, wherein the artificial marble further comprises at least one of a crosslinking agent, a crosslinking accelerator, a defoaming agent, a dispersing agent, a coupling agent and a pigment.
The artificial marble according to claim 1, wherein the artificial marble has a thickness of 2 to 4 mm.
The artificial marble according to claim 1, wherein the artificial marble has a flexural strength of 60 to 65 MPa of a 3 mm thick specimen measured according to ASTM D790.
Firstly applying a resin composition for forming a resin layer on the release film;
Laminating a glass fiber bale having a thickness of 100 to 200 mu m on the coated resin composition;
Applying a resin composition to the upper part of the glass fiber bale secondarily to impregnate the glass fiber veil; And
And curing the resin composition. ≪ RTI ID = 0.0 > 11. < / RTI >
The method according to claim 8, wherein the resin composition comprises at least one of an acrylic resin syrup, an epoxy resin syrup, and a polyurethane resin syrup.
The resin composition according to claim 9, wherein the resin composition is an inorganic filler comprising at least one of silica, alumina, calcium carbonate, calcium hydroxide, aluminum hydroxide, magnesium hydroxide, pearlite, vermiculite, smectite and bentonite with respect to 100 parts by weight of the resin syrup And further comprising not more than 500 parts by weight of the composition.
The method according to claim 8, wherein the resin composition further comprises at least one of a crosslinking agent, a crosslinking accelerator, a defoaming agent, a dispersing agent, a coupling agent and a pigment.
The method according to claim 8, wherein the thickness of the first resin composition is 2 to 3 mm and the thickness of the second resin composition is 2 to 3 mm.
The method according to claim 8, wherein the artificial marble has a thickness of 2 to 4 mm.
9. The method of claim 8, wherein the curing is performed at 40 to < RTI ID = 0.0 > 60 C. < / RTI >

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