WO2008091063A1 - Artificial marble having various designs and process for preparing the same - Google Patents

Artificial marble having various designs and process for preparing the same Download PDF

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Publication number
WO2008091063A1
WO2008091063A1 PCT/KR2007/006586 KR2007006586W WO2008091063A1 WO 2008091063 A1 WO2008091063 A1 WO 2008091063A1 KR 2007006586 W KR2007006586 W KR 2007006586W WO 2008091063 A1 WO2008091063 A1 WO 2008091063A1
Authority
WO
WIPO (PCT)
Prior art keywords
sheet
artificial marble
chips
adhesive
chip
Prior art date
Application number
PCT/KR2007/006586
Other languages
French (fr)
Inventor
Hae-Seung Ko
Keuk-Pil Bahng
Yeong-Hyeon Kim
Original Assignee
Lg Chem, Ltd.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Lg Chem, Ltd. filed Critical Lg Chem, Ltd.
Priority to EP07851557A priority Critical patent/EP2132152A4/en
Priority to CN2007800503329A priority patent/CN101589002B/en
Publication of WO2008091063A1 publication Critical patent/WO2008091063A1/en

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Classifications

    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B26/00—Compositions of mortars, concrete or artificial stone, containing only organic binders, e.g. polymer or resin concrete
    • C04B26/02—Macromolecular compounds
    • C04B26/04—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • C04B26/06—Acrylates
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65F—GATHERING OR REMOVAL OF DOMESTIC OR LIKE REFUSE
    • B65F1/00—Refuse receptacles; Accessories therefor
    • B65F1/0033—Refuse receptacles; Accessories therefor specially adapted for segregated refuse collecting, e.g. receptacles with several compartments; Combination of receptacles
    • B65F1/0053—Combination of several receptacles
    • B65F1/0073—Flexible receptacles fixed on a frame or in an enclosure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B44—DECORATIVE ARTS
    • B44F—SPECIAL DESIGNS OR PICTURES
    • B44F9/00—Designs imitating natural patterns
    • B44F9/04—Designs imitating natural patterns of stone surfaces, e.g. marble
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65F—GATHERING OR REMOVAL OF DOMESTIC OR LIKE REFUSE
    • B65F1/00—Refuse receptacles; Accessories therefor
    • B65F1/04—Refuse receptacles; Accessories therefor with removable inserts
    • B65F1/06—Refuse receptacles; Accessories therefor with removable inserts with flexible inserts, e.g. bags or sacks
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65F—GATHERING OR REMOVAL OF DOMESTIC OR LIKE REFUSE
    • B65F1/00—Refuse receptacles; Accessories therefor
    • B65F1/14—Other constructional features; Accessories
    • B65F1/141—Supports, racks, stands, posts or the like for holding refuse receptacles
    • B65F1/1415—Supports, racks, stands, posts or the like for holding refuse receptacles for flexible receptables, e.g. bags, sacks
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65F—GATHERING OR REMOVAL OF DOMESTIC OR LIKE REFUSE
    • B65F1/00—Refuse receptacles; Accessories therefor
    • B65F1/14—Other constructional features; Accessories
    • B65F1/1468—Means for facilitating the transport of the receptacle, e.g. wheels, rolls
    • B65F1/1473—Receptacles having wheels
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65F—GATHERING OR REMOVAL OF DOMESTIC OR LIKE REFUSE
    • B65F2210/00—Equipment of refuse receptacles
    • B65F2210/18—Suspending means
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65F—GATHERING OR REMOVAL OF DOMESTIC OR LIKE REFUSE
    • B65F2220/00—Properties of refuse receptacles
    • B65F2220/106—Collapsible
    • B65F2220/1063—Collapsible foldable
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
    • C04B2111/00612—Uses not provided for elsewhere in C04B2111/00 as one or more layers of a layered structure
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/54—Substitutes for natural stone, artistic materials or the like
    • C04B2111/542—Artificial natural stone
    • C04B2111/545—Artificial marble

Definitions

  • the present invention relates to an artificial marble having various surface designs and a process for preparing the same. More particularly, the present invention relates to an artificial marble having various exterior designs and a process for preparing the same, which comprises: inserting an exterior- design sheet using chips into a mold; pouring a base binder paste into the mold over the exterior-design sheet; vibrating the mold by use of a vibrator to remove air bubbles contained in the base binder paste; and performing curing and surface- treatment operations on the molded article.
  • artificial marbles used as exterior or interior constructional materials for buildings have been prepared by mixing a variety of decorative chips into a base binder paste, pressing or casting the mixture, and finally, performing a surface treatment on the resultant article, to provide the prepared artificial marble product with a granite exterior design.
  • 0081652 discloses an architectural panel having a double-layer structure consisting of a waste urethane substrate and a marble layer.
  • the disclosed architectural panel has no connection with an artificial marble, and there still exists no process for preparing an artificial marble using a chip sheet as proposed by the present invention.
  • Korean Patent Registration No. 409084 discloses a multilayered artificial marble panel for use in prefabricated bathroom walls, which is devised for the sake of reducing plastic chips.
  • Patent still does not deal with the preparation of an artificial marble using a chip sheet. Disclosure of Invention Technical Problem
  • the present invention has been made in view of the above problems, and it is an object of the present invention to provide an artificial marble having various exterior designs and a process for preparing the same.
  • an artificial marble which is formed by using a chip sheet prepared by transferring an adhesive onto a sheet to have a predetermined pattern and scattering chips over the sheet so that the chips are attached to the pattern transferred onto the sheet, in which the chips are remained with the pattern in the artificial marble after the sheet is removed from the artificial marble.
  • the adhesive is selected to ensure sufficient adhesiveness between the sheet and the chips.
  • the adhesive may be at least one selected from a polyvinyl chloride (PVC) sol, a thermosetting acryl adhesive, a thermosetting epoxy adhesive, a methylmethacrylate (MMA) sol containing a hardener, and an unsaturated polyester (UPE) sol containing a hardener. It is essential that the adhesive is a thermosetting adhesive so as not to be hardened at a room temperature to assure efficient transfer of the adhesive onto the sheet at a room temperature.
  • the chips may be at least one selected from resin chips including, for example, polymethylmethacrylate (PMMA) resin chips, natural marble chips obtained by crushing a natural marble, glass chips, colored chips, and other scattable chips.
  • the sheet must have easily separable and surface abrasive natures, and may be a paper film, a resin film, a glass film, or the like.
  • the sheet is preferably made of a polyethyleneterepthalate (PET) film.
  • the artificial marble is used as an exterior or interior constructional material for buildings, and may be a cement-based or resin-based artificial marble including, for example, acryl resin, unsaturated polyester resin, or epoxy resin.
  • a process for preparing an artificial marble comprising: transferring an adhesive onto a sheet to have a predetermined pattern; scattering chips over the sheet to prepare a chip sheet having the chips being attached to the pattern transferred onto the sheet; forming the artificial marble by using the chip sheet; and removing the sheet.
  • the process may further comprise: removing extra chips not attached to the sheet after curing the chip sheet.
  • the adhesive may be transferred by an embossing roll method, a screen printing method, a stamping method, or the like.
  • the artificial marble is formed by inserting the chip sheet into a mold; filling the mold with a base paste; and removing air bubbles contained in the base paste by use of a vibrator.
  • the sheet may be removed by releasing the sheet after completing the forming of the artificial marble, or by performing a surface grinding operation on the formed artificial marble.
  • an artificial marble used as an exterior or interior constructional material for buildings, by use of a press or vibrator
  • a chip sheet of various designs is prepared by use of a chip scattering device.
  • the mold is filled with a paste to prepare an artificial marble.
  • the resultant artificial marble is subjected to general curing and surface-treatment operations, to achieve various colors and designs of artificial marble products capable of satisfying different tastes of customers.
  • FIG. 1 is a flow chart illustrating a process for preparing an artificial marble according to the present invention
  • FIG. 2 is a schematic diagram illustrating a process for preparing a chip sheet for providing the artificial marble according to the present invention with a desired exterior design
  • FIG. 3 is a schematic perspective view of the chip sheet according to the present invention.
  • FIG. 4 is a perspective view illustrating a detailed procedure of the process for preparing the artificial marble according to the present invention.
  • FIG. 1 is a flow chart illustrating a process for preparing an artificial marble according to the present invention.
  • the process for preparing an artificial marble comprises a material measuring and filling operation, a mixing operation, an exterior-design sheet processing operation, a forming operation, a surface-treatment operation, and a cutting/inspecting/packaging operation.
  • FIG. 2 is a schematic diagram illustrating a process for preparing a chip sheet for providing the artificial marble according to the present invention with a desired exterior design. As shown, first, a sheet 70 is fed by a sheet feeding roll 10.
  • the sheet 70 preferably takes the form of a film made of paper, resin, glass, etc., and has a predetermined thickness.
  • the sheet 70 must have easily separable and surface abrasive natures.
  • the sheet 70 is preferably made of a water-resistant resin film, such as a polyethylene terephthalate (PET) film, etc.
  • an adhesive is transferred onto the sheet 70 by use of an adhesive transfer device 20, to have a predetermined pattern.
  • the adhesive transfer device 20 may include an embossing roll, a printing roll, a stamp, or the like having various patterns.
  • the adhesive may be selected from among a polyvinyl chloride (PVC) sol, a thermosetting acryl adhesive, a thermosetting epoxy adhesive, a methylmethacrylate (MMA) sol containing a hardener, an unsaturated polyester
  • the chips 80 may be selected from among resin chips using polymethylmethacrylate (PMMA) resin, glass chips, colored-glass chips, natural marble chips obtained by crushing a natural marble, colored natural marble chips obtained by coloring the crushed natural marble chips, and other scattable chips.
  • PMMA polymethylmethacrylate
  • the chips scattered onto a specific portion of the sheet 70 where no adhesive is applied, i.e. the not-attached chips are removed by a use of chip collecting device 50.
  • chip collecting device 50 a chip sheet having various designs can be obtained.
  • the completed chip sheet is guided to a sheet recovery roll 60.
  • FIG. 3 is a schematic perspective view of the chip sheet, and illustrates an exterior design in which a plurality of chips 80 are attached to the sheet 70 to create a star pattern. It will be appreciated that, in addition to the illustrated star pattern, a variety of exterior designs can be created, and furthermore, other discriminative designs can be obtained by use of printing rolls having a variety of patterns and various designs of chips.
  • FIG. 4 is a perspective view illustrating a detailed procedure of the process for preparing the artificial marble according to the present invention. As shown, the previously prepared chip sheet of various designs is inserted onto the bottom of a forming mold 90 such that the chips 80 face upward.
  • the base binder paste 100 is formed in the mold 90 by operation of a press and a vibrator.
  • the vibrator serves to remove air bubbles contained in the base binder paste 100.
  • the used base binder paste 100 may include a resin (acryl, etc.) or a cement paste used in the preparation of a conventional artificial marble, and may be selected to have various colors for satisfying different tastes of customers.
  • the resulting formed article is sequentially subjected to a curing operation, separating operation, and sheet-release or conventional surface- grinding operation, to remove the sheet 70 while leaving only the chips 80.
  • a finished artificial marble product 11 having various exterior designs can be prepared.
  • the finished artificial marble product 11 has only the chips 80 without the sheet 70. Accordingly, by combining the plurality of chips 80, the finished artificial marble product 11 can achieve various exterior designs.
  • a cement-based artificial marble was prepared by use of colored glass chips and natural marble chips.
  • a PVC sol was poured over the screen net. Then, the screen net was rolled by a squeegee, such that the PVC sol was transferred onto the PET film to have a star pattern. Subsequently, after scattering colored glass chips having a diameter of 3 mm to 6 mm over the PET film, the PET film was shaken out such that extra colored glass chips scattered on a specific portion of the PET film where no PVC sol is applied are removed. Then, the PET film was baked in an oven at a temperature of 180°C for about 5 minutes, to cause gelling of the PVC sol. After the gelling of the PVC sol was completed, not-attached extra colored glass chips are again removed by shaking out the PET film.
  • the resultant PET sheet was put into a mold having a length of 450 mm, a width of 450 mm, and a thickness of 30 mm, such that the colored glass chips face upward. Then, a base cement paste was poured into the mold.
  • the used cement paste includes, based on 100 percent by weight of cement, 300 to 370 percent by weight of natural marble chips having a diameter of 1 mm to 9 mm, 30 to 100 percent by weight of natural marble powder (No. 100 to No. 350), 25 to 35 percent by weight of water, and 1 to 3 percent by weight of a water- reducing agent.
  • the mold is vibrated by use of a vibrator for 1 to 5 minutes, so as to remove air bubbles contained in the cement paste. Thereafter, the cement paste was cured for 12 hours under the condition of a temperature of 40 to 50 ° C and a constant humidity.
  • the formed cement paste article was separated from the mold and then, was subjected to conventional grinding and cutting operations, to obtain an artificial marble product having a length of 400 mm, a width of 400 mm, and a thickness of 20 mm and a colored glass star pattern at a surface thereof. It is noted during the grinding operation that the grinding depth must be less than the diameter of the colored glass chips (less than 3 mm to Meanwhile, for the sake of satisfying different tastes of customers, there is no limit in the exterior designs of artificial marble products and also, there is no limit in the kind of natural marble chips used in the cement paste.
  • the present invention provides an artificial marble capable of representing discriminative exterior designs using a chip sheet of various designs.
  • the present invention has the effect of not only providing the artificial marble with an aesthetic exterior design satisfying different tastes of customers, but also improving the reliability of products.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Ceramic Engineering (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Materials Engineering (AREA)
  • Structural Engineering (AREA)
  • Organic Chemistry (AREA)
  • Finishing Walls (AREA)

Abstract

Disclosed is an artificial marble used in an exterior or interior constructional material for buildings and a process for preparing the same. The artificial marble is prepared by use of a chip sheet, to have various design patterns at a surface thereof.

Description

ARTIFICIAL MARBLE HAVING VARIOUS DESIGNS AND PROCESS FOR PREPARING THE SAME
Technical Field
The present invention relates to an artificial marble having various surface designs and a process for preparing the same. More particularly, the present invention relates to an artificial marble having various exterior designs and a process for preparing the same, which comprises: inserting an exterior- design sheet using chips into a mold; pouring a base binder paste into the mold over the exterior-design sheet; vibrating the mold by use of a vibrator to remove air bubbles contained in the base binder paste; and performing curing and surface- treatment operations on the molded article.
Background Art
Conventionally, artificial marbles used as exterior or interior constructional materials for buildings have been prepared by mixing a variety of decorative chips into a base binder paste, pressing or casting the mixture, and finally, performing a surface treatment on the resultant article, to provide the prepared artificial marble product with a granite exterior design.
In the above-described conventional process for preparing artificial marbles, however, there is a problem that the prepared artificial marble products have a limitation in the representation of various exterior designs. As one example, Korean Patent Laid-Open Publication No. 2003-
0081652 discloses an architectural panel having a double-layer structure consisting of a waste urethane substrate and a marble layer. However, the disclosed architectural panel has no connection with an artificial marble, and there still exists no process for preparing an artificial marble using a chip sheet as proposed by the present invention.
As another example, Korean Patent Registration No. 409084 discloses a multilayered artificial marble panel for use in prefabricated bathroom walls, which is devised for the sake of reducing plastic chips. However, the disclosed
Patent still does not deal with the preparation of an artificial marble using a chip sheet. Disclosure of Invention Technical Problem
Therefore, the present invention has been made in view of the above problems, and it is an object of the present invention to provide an artificial marble having various exterior designs and a process for preparing the same.
Technical Solution
In accordance with an aspect of the present invention, the above and other objects can be accomplished by the provision of an artificial marble which is formed by using a chip sheet prepared by transferring an adhesive onto a sheet to have a predetermined pattern and scattering chips over the sheet so that the chips are attached to the pattern transferred onto the sheet, in which the chips are remained with the pattern in the artificial marble after the sheet is removed from the artificial marble.
The adhesive is selected to ensure sufficient adhesiveness between the sheet and the chips. The adhesive may be at least one selected from a polyvinyl chloride (PVC) sol, a thermosetting acryl adhesive, a thermosetting epoxy adhesive, a methylmethacrylate (MMA) sol containing a hardener, and an unsaturated polyester (UPE) sol containing a hardener. It is essential that the adhesive is a thermosetting adhesive so as not to be hardened at a room temperature to assure efficient transfer of the adhesive onto the sheet at a room temperature. The chips may be at least one selected from resin chips including, for example, polymethylmethacrylate (PMMA) resin chips, natural marble chips obtained by crushing a natural marble, glass chips, colored chips, and other scattable chips.
The sheet must have easily separable and surface abrasive natures, and may be a paper film, a resin film, a glass film, or the like. In particular, the sheet is preferably made of a polyethyleneterepthalate (PET) film.
The artificial marble is used as an exterior or interior constructional material for buildings, and may be a cement-based or resin-based artificial marble including, for example, acryl resin, unsaturated polyester resin, or epoxy resin. In accordance with another aspect of the present invention, there is provided a process for preparing an artificial marble comprising: transferring an adhesive onto a sheet to have a predetermined pattern; scattering chips over the sheet to prepare a chip sheet having the chips being attached to the pattern transferred onto the sheet; forming the artificial marble by using the chip sheet; and removing the sheet.
For the sake of efficient preparation of the chip sheet, the process may further comprise: removing extra chips not attached to the sheet after curing the chip sheet. The adhesive may be transferred by an embossing roll method, a screen printing method, a stamping method, or the like.
Preferably, the artificial marble is formed by inserting the chip sheet into a mold; filling the mold with a base paste; and removing air bubbles contained in the base paste by use of a vibrator. The sheet may be removed by releasing the sheet after completing the forming of the artificial marble, or by performing a surface grinding operation on the formed artificial marble.
According to the present invention, in a process for preparing an artificial marble, used as an exterior or interior constructional material for buildings, by use of a press or vibrator, first, a chip sheet of various designs is prepared by use of a chip scattering device. Then, after inserting the chip sheet into a mold, the mold is filled with a paste to prepare an artificial marble. The resultant artificial marble is subjected to general curing and surface-treatment operations, to achieve various colors and designs of artificial marble products capable of satisfying different tastes of customers.
Description of Drawings
The above and other objects, features and other advantages of the present invention will be more clearly understood from the following detailed description taken in conjunction with the accompanying drawings, in which:
FIG. 1 is a flow chart illustrating a process for preparing an artificial marble according to the present invention; FIG. 2 is a schematic diagram illustrating a process for preparing a chip sheet for providing the artificial marble according to the present invention with a desired exterior design;
FIG. 3 is a schematic perspective view of the chip sheet according to the present invention; and
FIG. 4 is a perspective view illustrating a detailed procedure of the process for preparing the artificial marble according to the present invention.
Best Mode
Now, the present invention will be described in detail with reference to the accompanying drawings.
FIG. 1 is a flow chart illustrating a process for preparing an artificial marble according to the present invention. As shown, the process for preparing an artificial marble comprises a material measuring and filling operation, a mixing operation, an exterior-design sheet processing operation, a forming operation, a surface-treatment operation, and a cutting/inspecting/packaging operation.
FIG. 2 is a schematic diagram illustrating a process for preparing a chip sheet for providing the artificial marble according to the present invention with a desired exterior design. As shown, first, a sheet 70 is fed by a sheet feeding roll 10.
The sheet 70 preferably takes the form of a film made of paper, resin, glass, etc., and has a predetermined thickness. The sheet 70 must have easily separable and surface abrasive natures. In consideration of the fact that a paper film tends to be easily wet, the sheet 70 is preferably made of a water-resistant resin film, such as a polyethylene terephthalate (PET) film, etc.
Next, an adhesive is transferred onto the sheet 70 by use of an adhesive transfer device 20, to have a predetermined pattern. The adhesive transfer device 20 may include an embossing roll, a printing roll, a stamp, or the like having various patterns.
The adhesive may be selected from among a polyvinyl chloride (PVC) sol, a thermosetting acryl adhesive, a thermosetting epoxy adhesive, a methylmethacrylate (MMA) sol containing a hardener, an unsaturated polyester
(UPE) sol containing a hardener, etc. After the adhesive is completely transferred onto the sheet 70, various kinds of chips 80 having different colors and sizes from one another are scattered over the sheet 70 by use of a chip scattering device 30.
The chips 80 may be selected from among resin chips using polymethylmethacrylate (PMMA) resin, glass chips, colored-glass chips, natural marble chips obtained by crushing a natural marble, colored natural marble chips obtained by coloring the crushed natural marble chips, and other scattable chips.
Subsequently, after hardening the resultant chip sheet by use of a drying device 40, the chips scattered onto a specific portion of the sheet 70 where no adhesive is applied, i.e. the not-attached chips are removed by a use of chip collecting device 50. In this way, a chip sheet having various designs can be obtained. The completed chip sheet is guided to a sheet recovery roll 60.
FIG. 3 is a schematic perspective view of the chip sheet, and illustrates an exterior design in which a plurality of chips 80 are attached to the sheet 70 to create a star pattern. It will be appreciated that, in addition to the illustrated star pattern, a variety of exterior designs can be created, and furthermore, other discriminative designs can be obtained by use of printing rolls having a variety of patterns and various designs of chips.
FIG. 4 is a perspective view illustrating a detailed procedure of the process for preparing the artificial marble according to the present invention. As shown, the previously prepared chip sheet of various designs is inserted onto the bottom of a forming mold 90 such that the chips 80 face upward.
Next, after pouring a base binder paste 100 into the forming mold 90, the base binder paste 100 is formed in the mold 90 by operation of a press and a vibrator. Here, the vibrator serves to remove air bubbles contained in the base binder paste 100.
In this case, the used base binder paste 100 may include a resin (acryl, etc.) or a cement paste used in the preparation of a conventional artificial marble, and may be selected to have various colors for satisfying different tastes of customers. Finally, the resulting formed article is sequentially subjected to a curing operation, separating operation, and sheet-release or conventional surface- grinding operation, to remove the sheet 70 while leaving only the chips 80. In this way, a finished artificial marble product 11 having various exterior designs can be prepared. In the present invention, as a result of removing the sheet 70, the finished artificial marble product 11 has only the chips 80 without the sheet 70. Accordingly, by combining the plurality of chips 80, the finished artificial marble product 11 can achieve various exterior designs. [Example 1]
A cement-based artificial marble was prepared by use of colored glass chips and natural marble chips.
First, after a previously designed star-shaped screen net was put on a PET film, a PVC sol was poured over the screen net. Then, the screen net was rolled by a squeegee, such that the PVC sol was transferred onto the PET film to have a star pattern. Subsequently, after scattering colored glass chips having a diameter of 3 mm to 6 mm over the PET film, the PET film was shaken out such that extra colored glass chips scattered on a specific portion of the PET film where no PVC sol is applied are removed. Then, the PET film was baked in an oven at a temperature of 180°C for about 5 minutes, to cause gelling of the PVC sol. After the gelling of the PVC sol was completed, not-attached extra colored glass chips are again removed by shaking out the PET film.
The resultant PET sheet was put into a mold having a length of 450 mm, a width of 450 mm, and a thickness of 30 mm, such that the colored glass chips face upward. Then, a base cement paste was poured into the mold. In this case, the used cement paste includes, based on 100 percent by weight of cement, 300 to 370 percent by weight of natural marble chips having a diameter of 1 mm to 9 mm, 30 to 100 percent by weight of natural marble powder (No. 100 to No. 350), 25 to 35 percent by weight of water, and 1 to 3 percent by weight of a water- reducing agent. After the cement paste was poured into the mold, the mold is vibrated by use of a vibrator for 1 to 5 minutes, so as to remove air bubbles contained in the cement paste. Thereafter, the cement paste was cured for 12 hours under the condition of a temperature of 40 to 50 °C and a constant humidity.
After being completely cured, the formed cement paste article was separated from the mold and then, was subjected to conventional grinding and cutting operations, to obtain an artificial marble product having a length of 400 mm, a width of 400 mm, and a thickness of 20 mm and a colored glass star pattern at a surface thereof. It is noted during the grinding operation that the grinding depth must be less than the diameter of the colored glass chips (less than 3 mm to Meanwhile, for the sake of satisfying different tastes of customers, there is no limit in the exterior designs of artificial marble products and also, there is no limit in the kind of natural marble chips used in the cement paste.
Industrial Applicability
As apparent from the above description, the present invention provides an artificial marble capable of representing discriminative exterior designs using a chip sheet of various designs. As a result, the present invention has the effect of not only providing the artificial marble with an aesthetic exterior design satisfying different tastes of customers, but also improving the reliability of products.
Although the preferred embodiment of the present invention has been disclosed for illustrative purposes, those skilled in the art will appreciate that various modifications, additions and substitutions are possible, without departing from the scope and spirit of the invention as disclosed in the accompanying claims.

Claims

1. An artificial marble which is formed by using a chip sheet prepared by transferring an adhesive onto a sheet to have a predetermined pattern and scattering chips over the sheet so that the chips are attached to the pattern transferred onto the sheet, in which the chips are remained with the pattern in the artificial marble after the sheet is removed from the artificial marble.
2. The artificial marble according to claim 1, wherein the adhesive is at least one selected from a polyvinyl chloride (PVC) sol, a thermosetting acryl adhesive, a thermosetting epoxy adhesive, a methylmethacrylate (MMA) sol containing a hardener, and an unsaturated polyester (UPE) sol containing a hardener.
3. The artificial marble according to claim 1, wherein the chips are at least one selected from resin chips, natural marble chips, and glass chips.
4. The artificial marble according to claim 1, wherein the chips are colored chips.
5. The artificial marble according to claim 1, wherein the sheet is a paper film, a resin film, or a glass film.
6. The artificial marble according to claim 1, wherein the artificial marble is a cement-based or resin-based artificial marble.
7. A process for preparing an artificial marble comprising: transferring an adhesive onto a sheet to have a predetermined pattern; scattering chips over the sheet to prepare a chip sheet having the chips being attached to the pattern transferred onto the sheet; forming the artificial marble by using the chip sheet; and removing the sheet.
8. The process according to claim 7, further comprising: removing extra chips not attached to the sheet after curing the chip sheet.
9. The process according to claim 7, wherein the adhesive is transferred by using an embossing roll, a screen printing, or a stamp.
10. The process according to claim 7, wherein the artificial marble is formed by the steps of: inserting the chip sheet into a mold; filling the mold with a base paste; and removing air bubbles contained in the base paste by use of a vibrator.
11. The process according to claim 7, wherein the sheet is removed by releasing the sheet after completing the forming of the artificial marble, or by a surface grinding operation on the formed artificial marble.
PCT/KR2007/006586 2007-01-26 2007-12-17 Artificial marble having various designs and process for preparing the same WO2008091063A1 (en)

Priority Applications (2)

Application Number Priority Date Filing Date Title
EP07851557A EP2132152A4 (en) 2007-01-26 2007-12-17 Artificial marble having various designs and process for preparing the same
CN2007800503329A CN101589002B (en) 2007-01-26 2007-12-17 Artificial marble having various designs and process for preparing the same

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KR101304149B1 (en) * 2010-09-27 2013-09-05 (주)엘지하우시스 Forming mold with dual structure and method of manufacturing exterior panel for household electric appliance using the forming mold
KR101255318B1 (en) * 2011-12-05 2013-04-15 우리산업기술개발 주식회사 Manufacturing Method for Artificial Stone with Porous Surface
CN104385566A (en) * 2014-09-23 2015-03-04 捷美特株式会社 Artificial marble with formed patterns, and manufacturing method thereof
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CN104496274A (en) * 2014-12-15 2015-04-08 田忠和 Fireproof artificial quartz stone plate and manufacturing method thereof
US20200047372A1 (en) * 2018-08-13 2020-02-13 Myeong Hwa Chung Artificial stone slab with integrally formed pattern and manufacturing method for the same
KR102207950B1 (en) 2020-08-24 2021-01-26 곽호진 Construction Method of Building Walls Using Transparent Sheets
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EP2132152A4 (en) 2010-01-20
CN101589002B (en) 2012-10-17
CN101589002A (en) 2009-11-25
KR100888334B1 (en) 2009-03-12
KR20080070345A (en) 2008-07-30

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