WO2017003081A1

WO2017003081A1 - Lightweight artificial marble and manufacturing method therefor

Info

Publication number: WO2017003081A1
Application number: PCT/KR2016/004654
Authority: WO
Inventors: 황철연; 강한주; 손창호
Original assignee: 롯데첨단소재 주식회사
Priority date: 2015-06-30
Filing date: 2016-05-03
Publication date: 2017-01-05
Also published as: KR20170003313A

Abstract

An artificial marble of the present invention comprises: a surface layer comprising first particles having an average diameter of approximately 0.1-1.5 mm and a specific gravity of approximately 2-3, and second particles having an average diameter of approximately 1-45 μm and a specific gravity of approximately 2-3; and an inner layer formed on one surface of the surface layer, and comprising third particles having an average diameter of approximately 2-6 mm and a specific gravity of approximately 0.1-1.5. The surface layer and the inner layer of the artificial marble share a matrix, and thus interlayer adhesive strength is excellent and a step for attaching the surface layer and the inner layer to each other is unnecessary.

Description

【Specification】

[Name of invention]

Lightweight artificial marble and its manufacturing method [technical field]

The present invention relates to a lightweight artificial marble and a method of manufacturing the same. More specifically, the present invention relates to a lightweight artificial marble and a method for manufacturing the same, in which the surface layer and the inner layer share a matrix and do not require a bonding process between the surface layer and the inner layer.

Background Art

Silica-based, quartz-based or acrylic artificial marble is widely used because of the same texture as natural stone, but there is a problem that handling is difficult due to heavy weight during processing or construction.

In order to solve this problem, conventionally, the inner layer made of a lightweight material such as compressed wood and a surface layer acting as a marble surface is first produced as a thin slab, and then the surface layer and the inner layer are independently manufactured. In this way, the artificial marble was manufactured to reduce the overall weight and maintain the thickness.

However, the above-described manufacturing method has to produce the surface layer and the inner layer separately from each other, and since the process of adhering the inner layer to the surface layer is required separately, there is a problem that the overall manufacturing time and cost of the artificial marble increases. In addition, it is difficult to bond the surface layer and the inner layer having a surface having heterogeneous characteristics, and there is a fear that separation phenomenon of the surface layer and the inner layer due to weakening of adhesive force may occur.

Background art of the present invention is disclosed in Republic of Korea No. 1164878.

[Detailed Description of the Invention]

[Technical problem]

SUMMARY OF THE INVENTION An object of the present invention is to provide a lightweight artificial marble and a method for producing the same, in which the surface layer and the inner layer share a matrix, and have excellent interlayer adhesion, and do not require a bonding process between the surface layer and the inner layer. Another object of the present invention is to provide a lightweight artificial marble and a method of manufacturing the same that can prevent the appearance defects of the surface layer by the inner layer component.

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

Technical Solution

One aspect of the invention relates to artificial marble. The artificial marble has a surface layer comprising a first particle having an average particle diameter of about 0.1 to about 1.5 GPa, a specific particle size of about 2 to about 3, and a second particle having an average particle diameter of about 1 to about 45, or about 2 to about 3; And an inner layer formed on one surface of the surface layer, the inner layer including third particles having an average particle diameter of about 2 to about 6 mm, and about 0.1 to about 1.5.

In an embodiment, the surface layer and the inner layer can share a matrix resin. In embodiments, the first particles and the second particles may each independently include one or more of silica, alumina, calcium carbonate, aluminum hydroxide, and magnesium hydroxide.

In embodiments, the third particles may comprise one or more of pearlite, vermiclite, smectite and bentonite.

In embodiments, the matrix resin may include at least one of polyester resin, acrylic resin, epoxy resin, and polyurethane resin.

In embodiments, the thickness ratio of the surface layer and the inner layer may be about 1: 1: 1 to about 6.

In embodiments, the artificial marble may further include at least one of an inorganic filler, a crosslinking agent, a crosslinking accelerator, and a pigment except for the first particles, the second particles, and the third particles.

Another aspect of the invention relates to a method for producing the artificial marble. The preparation method comprises a first particle having an average particle diameter of about 0.01 to about 1.5 mm, a specific gravity of about 2 to about 3, a second particle having an average particle diameter of about 1 to about 45 m, a specific gravity of about 2 to about 3, and a matrix resin. To a first mixture, and an average particle diameter of about 0.01 to about 1.5 GPa, a first particle having a specific gravity of about 2 to about 3, a second particle having an average particle diameter of about 1 to about 45 μπι, a specific gravity of about 2 to about 3, and A third having an average particle diameter of about 2 to about 6 mm and a specific gravity of about 0.1 to about 1.5 Pouring a second mixture comprising particles and matrix resin into a mold; Subjecting the first particles and the second particles to a lower portion of the mold and vibrating the third particles to be positioned separately on the upper portion of the mold; And curing the matrix resin.

In embodiments, the first mixture may comprise about 45 to about 80 weight percent of the first particles, about 10 to about 40 weight percent of the second particles and about 5 to about 15 weight percent of the matrix resin.

In embodiments, the second mixture comprises about 1 to about 10 weight percent of the first particles, about 15 to about 40 weight percent of the second particles, about 20 to about 60 weight percent of the third particles and the matrix And about 5 to about 30 weight percent resin.

In embodiments, the ratio of increasing the first and crab mixtures may be about 1: about 0.5 to about 1: about 3.

In embodiments, the vibration may be performed in a vertical vibration manner in which the motor speed is about 2,000 to about 4,000 rpm.

In embodiments, the first mixture and the second mixture may further include at least one of an inorganic layering agent, a crosslinking agent, a crosslinking accelerator and a pigment except for the first particles, the second particles, and the third particles. .

【Effects of the Invention】

According to the present invention, the surface layer and the inner layer share a matrix, so that the adhesion between the layers is excellent, the adhesion process between the surface layer and the inner layer is unnecessary, and the lightweight artificial marble and its manufacture can prevent the appearance defect of the surface layer by the inner layer composition. It has the effect of the invention providing a method.

[Brief Description of Drawings]

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

2 is a view showing a method of manufacturing artificial marble according to an embodiment of the present invention.

3 is a photograph of a cross section of the artificial marble prepared according to Example 1 of the present invention. [Best form for implementation of the invention]

Hereinafter, with reference to the accompanying drawings, it will be described in detail the present invention. However, the technology disclosed in the present invention is not limited to the embodiments described herein and may be embodied in other forms. However, the embodiments introduced herein are provided to enable the disclosed contents to be thorough and complete, and to fully convey the spirit of the present invention to those skilled in the art. In order to clearly express the components in the drawings, the sizes, such as the width and the thickness of the components, are shown to be enlarged somewhat. In addition, although only a part of the components are shown for convenience of description, those skilled in the art will be able to easily understand the rest of the components. When described in the drawings as a whole, it is described at the observer's point of view, and when one element is referred to as being positioned above or below another element, the element may be positioned directly above or below another element, or an additional element may be interposed therebetween. It includes all meanings that can be, and the criteria of "upper", "lower" is based on the drawings. In addition, one of ordinary skill in the art may implement the spirit of the present invention in various other forms without departing from the technical spirit of the present invention. In addition, in the drawings, the same reference numerals refer to substantially the same elements.

On the other hand, the meaning of the terms described in the present invention will be understood as follows. Terms such as "first" or "second" are intended to distinguish one component from another, and the scope of rights should not be limited by these terms. For example, the first component may be called a second component, and similarly, the second component may also be called a first component.

Also, the singular forms “a,” “an” and “the” include the plural forms of expressions unless the context clearly indicates otherwise. It is to be understood that combinations of these are intended to be present and do not preclude the existence or addition of one or more other features or 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 is a lightweight artificial marble including a surface layer 10 and an inner layer 20, and has an average particle diameter of about 0.1 to about 1.5 μm and a specific gravity of about 2 to about 3 A surface layer 10 comprising a phosphorous first particle 12 and an average particle diameter of about 1 to about 45; c, a second particle 14 having a specific gravity of about 2 to about 3; And an inner layer 20 formed on one surface of the surface layer 10 and comprising third particles 22 having an average particle diameter of about 2 to about 6 mm and a specific gravity of about 0.1 to about 1.5.

In an embodiment, the surface layer 10 and the inner layer 20 may share a matrix resin. That is, the artificial marble 100 of the present invention may have a form in which the first particles 12, the second particles 14, and the third particles 22 are included in a layer separated form in the same matrix resin. As described above, the artificial marble 100 of the present invention is manufactured separately from the surface layer and the inner layer, and thus is an integrated form, not an adhesive form, and thus has excellent interlayer adhesion, and does not require an adhesion process between the surface layer and the inner layer.

In embodiments, the crab 1 particles 12 may be an inorganic layering agent having an average particle diameter of about 0.1 to about 1.5 mm, a specific gravity of about 2 to about 3, for example, an average particle diameter of about 0.1 to about 1.2 mm, a specific gravity of about 2.4 to about 2.6. have. With the second particles 14 in the above range, it is possible to produce an artificial marble having a beautiful appearance and having a texture of natural marble having excellent surface hardness. As the first particles 12, an inorganic filler having the above average particle diameter and specific gravity may be used without limitation, and may include, for example, one or more of silica, alumina, calcium carbonate, aluminum hydroxide, barium lactate, and magnesium hydroxide. have. In an embodiment, the second particle 14 can be an inorganic layering agent having an average particle diameter of about 1 to about 45 μπι, nasal about 2 to about 3, such as an average particle diameter of about 9 to about 13, nasal about 2.4 to about 2.6. . With the first particles 12 in the above range, it is possible to produce an artificial marble having a beautiful appearance and having a texture of natural marble having excellent surface hardness. As the second particle 14, an inorganic filler having the above average particle diameter and specific gravity may be used without limitation, and may include, for example, one or more of silica, alumina, calcium carbonate aluminum hydroxide, barium lactate, and magnesium hydroxide. .

In an embodiment, the third particle 22 is a light weight particle having an average particle diameter of about 2 to about 6 mm, a specific gravity of about 0.1 to about 1.5, for example, an average particle diameter of about 2 to about 4 mm, and about 0.5 to about 1. The first particle 12 having a small particle size and a large specific gravity due to vibration or the like in the above range. And the second particle 14 moves downward, and the third particle 22 having a large particle size and a small specific gravity may move upward. A layer separation phenomenon may occur, and the inner layer 20 and the surface layer 10 are formed. Can be. As the third particles 22, lightweight particles for artificial marble having the average particle diameter and specific gravity can be used without limitation. For example, the crab three particles may be pearlite, vermiculite, smectite ) And bentonite.

In an embodiment, the matrix resin can be used without limitation, the matrix resin used in known artificial marble. For example, a (unsaturated) polyester resin, an acrylic resin, an epoxy resin, a polyurethane resin, or a combination thereof can be used.

The polyester resin is not particularly limited, but is prepared by, for example, condensation reaction of an α, β-unsaturated dibasic acid or a mixture of the dibasic and saturated dibasic acids with a polyhydric alcohol, with a weight average molecular weight of about 1,000 to Polyester resins of about 5,000 g / mol can be used. The method for producing the polyester resin is not particularly limited. For example, the dibasic acid or the like is mixed with a polyhydric alcohol in a specific ratio (for example, moles of alcoholic hydroxyl groups / moles of carboxyl groups = about 0.8 to about 1.2). After the condensation reaction of the mixture at a temperature of about 140 to about 250 ^° C, under the inert gas stream such as carbon dioxide and / or nitrogen gas to remove the product water and gradually increase the temperature according to the progress of reaction It can manufacture.

Here, examples of the α, β-unsaturated dibasic acid and saturated dibasic acid include maleic anhydride, citraconic acid, fumaric acid, itaconic acid, and phthalic acid. ), Phthalic anhydride, isophthalic acid, terephthalic acid, terephthalic acid, succinic acid, adipic acid, sebacic acid and / or tetrahydrophthalic acid, and the like. Examples of 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 and / or glycerin; The polyester resin is, if necessary, acrylic acid, propionic acid And / or monobasic acids such as benzoic acid; Or trimellitic acid (tr imel lic acid) and / or polybasic acid of benzoles tetracarboxylic acid. The acrylic resin is not particularly limited, for example, methyl (meth) acrylate, ethyl (meth) acrylate, butyl (meth) acrylate, 2—ethyl nucleus (meth) acrylate, benzyl (meth) acrylate and The polymer of acrylic monomers, such as glycidyl (meth) acrylate and these mixtures, can be used.

Moreover, the said epoxy resin is not specifically limited, For example, bisphenol-A epoxy resin, bisphenol S-type epoxy resin tetraphenyl ethane epoxy resin, a phenol novolak-type epoxy resin, these mixtures, etc. can be used.

In an embodiment, the artificial marble 100 comprises inorganic layering agents, crosslinking agents, crosslinking accelerators, pigments, combinations thereof, etc., except for the first particles 12, the second particles 14, and the third particles 22. It may further include an additive.

As the inorganic layering agent, an inorganic layering agent used for preparing artificial marble except for the first particle 12, the second particle 14, and the third particle 22 may be used without limitation. In addition, the inorganic layering agent may have an average particle diameter of about 10 to about 200, but is not limited thereto.

As the crosslinking agent, a compound having a double bond in a molecule capable of crosslinking with the matrix resin can be used without limitation. For example, ethylene glycol di (meth) acrylate (EDMA), diethylene glycol di (meth) acrylate (2EDMA), triethylene glycol di (meth) acrylate (3EDMA), tetraethylene glycol di (meth) ) Acrylate (4EDMA), trimethylolpropane tri (meth) acrylate (TMPMA), 1, 6-diulicate di (meth) acrylate, polybutylene glycoldi (meth) acrylate, neopentyl glycoldi (meth) ) Acrylates, their mixtures and the like can be used.

The crosslinking promoter plays a role of promoting polymerization and curing reaction of the resin composition in the preparation of artificial marble. Examples of the crosslinking accelerator include diacyl peroxides such as benzoyl peroxide and dicumyl peroxide; Hydroperoxides such as butyl hydroperoxide, t-butyl hydroperoxide and cumyl hydroperoxide; t-butylperoxymaleic acid; t-butylhydroperoxybutylate; Acetyl peroxide; Lauroyl peroxide; Azobisisobutyronitrile; Azobisdimethylvaleronitrile; t-butyl peroxy neo-tecano Eight; t-amylperoxy-2-ethylnucleosanate and the like can be used, but is not limited thereto.

In an embodiment, the thickness ratio of the surface layer 10 and the inner layer 20 may be about 1: about 1 to about 1: about 6, for example about 1: about 1.5 to about 1: about 4. By reducing the overall weight in the above range and maintaining the thickness, it is possible to obtain a lightweight artificial marble easy to process. FIG. 2 is a view showing a method of manufacturing artificial marble according to an embodiment of the present invention. As shown in FIG. ₂ , the method of manufacturing artificial marble 100 includes low U particles 12 and second particles 14. ) And a first mixture 30 comprising a matrix resin (not shown) and a first particle 12, a second particle 14, a third particle 22 and a matrix resin (not shown) Pouring the second mixture 40 into the mold 50 (S10); Applying a vibration such that the first particles 12 and the crab particles 14 are positioned below the mold 50, and the third particles 22 are separated and positioned above the mold 50 (S20); And curing the matrix resin (not shown) by a method such as compression molding to prepare artificial marble 100 (S30).

In an embodiment, the Crab 1 mixture 30 comprises from about 45 to about 80 weight percent of the first particles 12, for example from about 50 to about 70 weight percent, from about 10 to about 40 weight percent of the second particles 14. For example, about 20 to about 40 percent by weight and about 5 to about 15 percent by weight of the matrix resin (not shown), for example about 7 to about 13 percent by weight. Beautiful appearance in the above range, it is possible to manufacture an artificial marble having a texture of natural marble excellent surface hardness.

In an embodiment, the Crab 2 mixture 40 comprises from about 1 to about 10 weight percent of the first particles 12, for example from about 4 to about 7 weight ¾>, from about 15 to about 40 weight of the second particles 14. ¾>, for example about 30 to about 40 weight percent, about 20 to about 60 weight percent of third particles 22, for example about 30 to about 50 weight ¾> and about 5 to about said matrix resin (not shown). About 30% by weight, for example about 15 to about 25% by weight. It is possible to manufacture a lightweight artificial marble in the above range.

In an embodiment, the weight ratio of the first complex 30 and the second complex 40 is about 1: about 0.5 to about 1: about 3, for example about 1: about 1.5 to about 1: about 2 Can be. remind The surface layer 10 and the inner layer 20 having the composition and the layer thickness in the range can be easily formed by layer separation, the appearance is beautiful and the surface hardness is excellent, the overall weight is reduced and the overall thickness can be maintained. You can get a lightweight artificial marble.

In embodiments, the specific gravity of the first complex 30 may be about 2 to about 2.5, for example about 2.2 to about 2.4, and the specific gravity of the second complex 40 may be about 1 to about 1.5, for example For example from about 1.2 to about 1.4. Layer separation by vibration in the above range may be easy.

In an embodiment, the vibration may be performed in a known vertical vibration method, for example, may be performed in a vertical vibration method in which the motor speed is about 2,000 to about 4,000 rpm.

In an embodiment, the curing of the matrix resin may be performed according to a known curing method in the preparation of artificial marble. For example, after molding the resultant layer separated by the vibration process to the product size by compression molding or the like, it may be to cure at least about 1 hour at a temperature of about 80 to about 120 ^° C.

In an embodiment, the first mixture 30 and / or the second mixture 40 may include inorganic layering agents, crosslinking agents, excluding the first particles 12, the low 12 particles 14 and the third particles 22, It may further include an additive including at least one of a crosslinking accelerator and a pigment. For example, the content of the inorganic layering agent may be about 500 parts by weight or less, for example, about 0.1 to about 450 parts by weight based on about 100 parts by weight of the matrix resin, but is not limited thereto. The content of the crosslinking agent and the crosslinking accelerator may be about 0.1 to about 10 parts by weight, for example, about 0.2 to about 5 parts by weight, based on about 100 parts by weight of the matrix resin, but is not limited thereto. In addition, the pigment content may be about 10 parts by weight or less, for example about 0.01 to about 5 parts by weight, based on about 100 parts by weight of the matrix resin, but is not limited thereto.

[Form for implementation of invention]

Hereinafter, the configuration and operation of the present invention through the preferred embodiment of the present invention will be described in more detail. However, it is presented as a preferred example of the present invention and in no sense can be construed as limiting the present invention. The information that is not described here will be omitted in the technical field can be inferred by those skilled in the art. Example

Example 1 Preparation of Artificial Marble

According to the composition and content of Table 1 below, silica particles having a particle size of 0.01 to 5.6 Pa, specific gravity of 2.43 as a system 1 particle (manufacturer: POLAT Inc., product name: PM G600), particle size of 45 or less as a second particle, specific gravity : 2.45 silica powder (manufacturer: 21st century, product name: SP-300), pearlite (average particle size: 2.36-4 mm, specific gravity: 0.5) as a third particle, and polyester resin (manufacturer: Aekyung Chemical, product name) as matrix resin : ATM 100) was mixed, and the first and second mixtures were prepared. Then, these were put into a mold having a size of 600 mm * 600 mm * 100 mm. Next, the mold is vibrated for 2 minutes by vertical vibration at a motor speed of 3,600 rpm and vacuum / vibration / compression molding at a pressure of 2 to 3 bar and a vacuum condition of -760 腿 Hg, at 1, 90 ^° C. The resin was cured for a time to prepare artificial marble. A cross section of the manufactured artificial marble is shown in FIG. 3.

[Table 1]

From the above results, the artificial marble prepared according to the embodiment of the present invention, the surface layer and the inner layer share a matrix, excellent interlayer adhesion, do not need the adhesion process of the surface layer and the inner layer, and the surface layer of the inner layer It can be seen that appearance defects can be prevented. In addition, it can be seen that the overall weight can be reduced and the thickness can be maintained, and the processing is easy. Simple modifications and variations of the present invention can be easily made by those skilled in the art, and all such modifications or changes can be seen to be included in the scope of the present invention.

Claims

[Range of request]

[Claim 1]

A surface layer comprising first particles having an average particle diameter of about 0.01 to about 1.5 GPa, specific particles of about 2 to about 3, and two particles of average particle diameter of about 1 to about 45 urn, specific gravity of about 2 to about 3; And

An artificial marble formed on one surface of the surface layer and including an inner layer including third particles having an average particle diameter of about 2 to about 6 mm 3 and a specific gravity of about 0.01 to about 1.5.

[Claim 2]

The artificial marble according to claim 1, wherein the surface layer and the inner layer share a matrix resin.

[Claim 3]

The artificial marble according to claim 1, wherein the first particles and the second particles each independently include one or more of silica, alumina, calcium carbonate, aluminum hydroxide, and magnesium hydroxide.

[Claim 4]

The artificial marble according to claim 1, wherein the third particles include at least one of pearlite, vermiclite, smectite, and bentonite.

[Claim 5]

3. The artificial marble according to claim 2, wherein the matrix resin comprises at least one of polyester resin, acrylic resin, epoxy resin and polyurethane resin.

[Claim 6]

The artificial marble according to claim 1, wherein the thickness ratio of the surface layer and the inner layer is about 1: 1: 1 to about 6.

[Claim 7]

The artificial marble according to claim 1, wherein the artificial marble further comprises at least one inorganic filler, a crosslinking agent, a crosslinking accelerator, and a pigment additive except for the first particles, the second particles, and the third particles.

[Claim 8]

A first mixture comprising a matrix particle having a mean particle size of about 0.01 to about 1.5 ram, a first particle having an abrasion of about 2 to about 3, a second particle having an average particle diameter of about 1 to about 45, a specific gravity of about 2 to about 3, and a matrix resin And an average particle diameter of about 0.01 to about 1.5 mm, a first particle having a specific gravity of about 2 to about 3, an average particle diameter of about 1 to about 45, a second particle having a specific gravity of about 2 to about 3, and an average particle diameter of about 2 to about Pour into the mold a second mixture comprising a matrix resin and a third particle of 6 mm, specific gravity about 0.1 to about 1.5;

Subjecting the first particles and the second particles to a lower portion of the mold and vibrating the third particles to be positioned separately on the upper portion of the mold; And

Method of producing artificial marble comprising the step of curing the matrix resin.

[Claim 9]

The method of claim 8, wherein the first mixture comprises about 45 to about 80 weight% of the first particles, about 10 to about 40 weight% of the second particles, and about 5 to about 15 weight% of the matrix resin. Method for producing artificial marble, characterized in that.

[Claim 10]

The method of claim 18, wherein the second mixture comprises about 1 to about 10 weight percent of the first particles, about 15 to about 40 weight percent of the second particles, about 20 to about 60 weight percent of the third particles, and And about 5 to about 30 weight percent of a matrix resin.

[Claim 11]

9. The method of claim 8, wherein the weight ratio of the first and second mixtures is about 1: about 0.5 to about 1: about 3.

[Claim 12]

10. The method of claim 8, wherein the vibration is performed in a vertical vibration manner in which a motor speed is about 2,000 to about 4,000 rpm.

[Claim 13]

The method of claim 8, wherein the first mixture and the second mixture further comprise at least one of an inorganic layering agent, a crosslinking agent, a crosslinking accelerator, and a pigment except for the first particles, the second particles, and the third particles. Method of manufacturing artificial marble, characterized in that.