WO2020138604A1

WO2020138604A1 - Artificial marble

Info

Publication number: WO2020138604A1
Application number: PCT/KR2019/007662
Authority: WO
Inventors: 정두교
Original assignee: 롯데케미칼 주식회사
Priority date: 2018-12-27
Filing date: 2019-06-25
Publication date: 2020-07-02
Also published as: KR102302680B1; KR20200081624A

Abstract

Provided is artificial marble comprising: an acrylic artificial marble body comprising a filler; and honeycomb cores which are located inside the acrylic artificial marble body and which have a lower specific gravity than the filler, wherein the acrylic artificial marble body is formed integrally.

Description

Artificial marble

The present invention relates to artificial marble.

Natural stones, such as granite and marble, have been used as architectural decoration materials since they have a beautiful surface pattern. Recently, as a material exhibiting high quality texture, it has been spotlighted, and its demand has been greatly increased in fields such as flooring, walls, and countertops. Due to this, it is impossible to satisfy the demand with expensive natural stone alone, and various types of artificial marble have been developed.

These artificial marbles are largely divided into two types, acrylic and unsaturated polyester, depending on the base resin used. Among these, acrylic artificial marble is used for various purposes due to its advantages such as transparency and high-quality texture.

Acrylic artificial marble uses aluminum hydroxide, talc, magnesium hydroxide, etc. as a filler. These fillers are generally effective in reinforcing the flame retardancy and/or mechanical properties of artificial marble because they can function as reinforcing materials and/or flame retardants.

However, the acrylic artificial marble using such a filler is difficult to transport and design depending on the specific gravity and weight of the material itself used as the filler. For example, in the case of an acrylic artificial marble finished product using aluminum hydroxide (assuming that the width, length, and thickness are 3680 mm Х 760 mm Х 12 mm, respectively), the finished product has a specific gravity of about 1.7 to 1.9, as well as about 55 kg to about It is a heavy object weighing about 65 kg. Therefore, when handling such artificial marble, it is necessary to use a dedicated transfer facility or to be transported by several people, and it is necessary to reflect the design in consideration of the load of artificial marble in the installation process. Accordingly, there is a need for a lightweight artificial marble that is capable of transporting artificial marble and solving design constraints.

As a method for reducing the weight of artificial marble, artificial marble in the form of plywood has been proposed in which artificial marble is thinly processed to a thickness of about 3 mm to about 6 mm thinner than a conventional thickness and a metal honeycomb core is adhered to the surface. However, in this case, an additional process of processing artificial marble and bonding the metal honeycomb core with a separate adhesive is required, and since the adhesive layer made of the adhesive and/or the adhesive is vulnerable to heat, thermoforming is impossible.

One embodiment is to provide a synthetic marble that can exhibit excellent thermal formability, as well as being lightweight compared to the existing artificial marble.

According to one embodiment, the acrylic artificial marble body including a filler; And

It is located inside the acrylic artificial marble body, a honeycomb core (Honeycomb core) having a lower specific gravity than the filler; includes, the acrylic artificial marble body is provided with an artificial marble formed integrally.

The acrylic artificial marble body may surround the honeycomb core so that the surface of the honeycomb core is not exposed.

The filler may include aluminum hydroxide, magnesium hydroxide, calcium carbonate, talc, or a combination thereof.

The acrylic artificial marble body may be obtained by curing the composition for forming an acrylic artificial marble body including the filler and the acrylic resin syrup.

The acrylic resin syrup may include an acrylic monomer and a polymer of the acrylic monomer.

The composition for forming the acrylic artificial marble body may further include an initiator, a crosslinking agent, a coupling agent, a surfactant, a reaction accelerator, an antistatic agent, an antibacterial agent, an antifoaming agent, a dispersing agent, a molecular weight modifier, an ultraviolet absorber, a colorant, or a combination thereof.

The honeycomb core may include a lattice layer including a plurality of honeycomb cells having a hollow, and a skin layer positioned on at least one surface of the cell lattice layer.

The honeycomb cell may have a diameter of 3 mm to 28 mm.

The lattice layer may include polypropylene, polystyrene, polyphenylene, polyamide, polycarbonate, or a combination thereof.

The skin layers may be located on opposite sides of the grid layer, respectively.

The skin layer may cover both sides of the grid layer facing each other so that the hollow is not filled.

The skin layer may be in direct contact with the acrylic artificial marble body.

The skin layer may include polypropylene, polystyrene, polyphenylene, polyamide, polycarbonate, glass fiber, or a combination thereof.

The skin layer includes a plurality of microfibers protruding from the surface, and the plurality of microfibers may be entangled with each other.

The honeycomb core may have a thickness of 3 mm to 6 mm.

The artificial marble may have a flat plate shape or a curved surface shape.

Artificial marble according to one embodiment is lighter than conventional marble and exhibits excellent thermoforming properties, and thus can be widely applied to fields requiring artificial marble of various shapes.

1 is a perspective view showing an artificial marble according to an embodiment,

2 is a cross-sectional view of II-II of FIG. 1,

3 is a cross-sectional view showing an example of processing of artificial marble according to an embodiment.

Hereinafter, embodiments of the present invention will be described in detail. However, this is presented as an example, and the present invention is not limited thereby, and the present invention is only defined by the scope of claims to be described later.

Unless otherwise defined, all terms (including technical and scientific terms) used in the present specification may be used as meanings commonly understood by those skilled in the art to which the present invention pertains. When a part of the specification "includes" a certain component, this means that other components may be further included instead of excluding other components unless specifically stated otherwise. Also, the singular form includes the plural form unless otherwise specified in the phrase.

The present inventors have researched a method to make the artificial marble lighter and to thermoform it in various shapes. As a result, when the acrylic artificial marble body is integrally formed on the honeycomb core using the composition for forming the acrylic artificial marble body, the honeycomb core is not included or the honeycomb core is bonded to the honeycomb core in the form of plywood. Thus, the present invention was completed by discovering that it is possible to provide artificial marble that exhibits both light and excellent thermal properties.

1 is a perspective view showing an artificial marble according to an embodiment.

In order to satisfy light weight and excellent thermoforming conditions, the artificial marble 100 according to an embodiment is located inside the acrylic artificial marble body 10 including a filler and the acrylic artificial marble body 10, but the filler Honeycomb core (20) having a lower specific gravity.

Referring to FIG. 1, the acrylic artificial marble body 10 may surround the honeycomb core 20. Specifically, the acrylic artificial marble body 10 may surround the honeycomb core 20 so that the surface of the honeycomb core 20 is not exposed to the outside.

In one implementation, the acrylic artificial marble body 10 is integrally formed. That is, the acrylic artificial marble 100 according to an embodiment may include an integral acrylic artificial marble body 10 in which a honeycomb core 20 is embedded.

Here, "one body" means that the components are separated from each other or two or more components exist as one body continuously connected, rather than connected to each other through a connecting portion. Therefore, the acrylic artificial marble body 10 according to one embodiment has a structure different from that of the artificial marble plates separated from each other by connecting them with adhesive, molding, sealing, or the like.

In one embodiment, the integral acrylic artificial marble body 10 may be obtained by applying and curing the composition for forming an acrylic artificial marble body including acrylic resin syrup, filler, and optional other additives.

Accordingly, the artificial marble 100 according to one embodiment may be manufactured through one process of curing after applying the composition for forming the acrylic artificial marble body to the honeycomb core 20, and the acrylic artificial marble body 10 ) Is formed in a form surrounding the honeycomb core 20, so there is no need to form a separate adhesive layer between the acrylic artificial marble body 10 and the honeycomb core 20.

Therefore, the artificial marble 100 according to one embodiment does not require a separate molding, sealing, etc. treatment to prevent exposure of a crack between two artificial marble plates arranged in the form of a honeycomb core or sandwich panel. , Since there is no separate adhesive layer, relatively free thermoforming is possible.

In one embodiment, the acrylic resin syrup constituting the composition for forming an acrylic artificial marble body is a component of the composition for forming an artificial marble body, and imparts basic properties due to the acrylic resin syrup to the composition for forming an artificial marble body. .

In one embodiment, the acrylic resin syrup may include an acrylic monomer and a polymer of the acrylic monomer. That is, the acrylic resin syrup may be one in which acrylic monomers and polyacrylates, which are polymers thereof, are dissolved.

As the acrylic monomer, methyl (meth)acrylate, ethyl (meth)acrylate, isopropyl (meth)acrylate, n-butyl (meth)acrylate, 2-ethyl hexyl (meth)acrylate, and the like can be used. .

Meanwhile, the content of each of the acrylic monomer and the polymer of the acrylic monomer in the acrylic resin syrup may be variously adjusted according to the properties of the artificial marble 100.

In one embodiment, the filler constituting the composition for forming the acrylic artificial marble body reinforces the mechanical properties of the artificial marble body 10 and low flame retardancy due to the acrylic system, while imparting natural stone texture to the artificial marble body 10 Can.

The filling material may include, for example, aluminum hydroxide, magnesium hydroxide, calcium carbonate, talc, or a combination thereof, so as to secure the mechanical properties and flame retardant reinforcing effects of the artificial marble body 10 described above. The materials may exhibit a specific gravity exceeding at least 2 g/cm ³ , for example, a specific gravity of about 2.1 g/cm ³ to about 4 g/cm ³ .

On the other hand, the content of the filler in the composition for forming an acrylic artificial marble body may be variously adjusted according to the flame retardancy, formability, processability, and natural stone texture targeted by the artificial marble.

In one embodiment, the composition for forming the acrylic artificial marble body may further include various additives to satisfy the target physical properties of the artificial marble body 10. The type of the additive is not particularly limited, but may include, for example, an initiator, a crosslinking agent, a coupling agent, a surfactant, a reaction accelerator, an antistatic agent, an antibacterial agent, an antifoaming agent, a dispersing agent, a molecular weight modifier, an ultraviolet absorber, a colorant, or a combination thereof. Can.

The type and/or amount of additives in the composition for forming an acrylic artificial marble body can be variously adjusted according to various properties targeted by the artificial marble.

In one embodiment, the honeycomb core 20 is located inside the acrylic artificial marble body 10 as shown in FIG. 1. The weight and/or volume occupied by the honeycomb core 20 in the artificial marble 100 is not particularly limited as long as the artificial marble 100 satisfies the target mechanical properties, flame retardancy, formability, and workability.

In one embodiment, the honeycomb core 20 may have a lower specific gravity than the filler included in the acrylic artificial marble body 10 described above. That is, the artificial marble 100 according to an embodiment has a lower specific gravity than the filler, and thus it is possible to lighten the artificial marble 100 by increasing the proportion occupied by the honeycomb core 20 in the artificial marble 100.

That is, in one embodiment, by controlling the weight and/or volume relationship between the honeycomb core 20 and the acrylic artificial marble body 10, the lightweight artificial marble 100 satisfies excellent mechanical properties, flame retardancy, formability, and workability. Can provide

Specifically, the honeycomb core 20 may include a lattice layer and a skin layer.

FIG. 2 is a cross-sectional view of II-II of FIG. 1.

Specifically, the honeycomb core 20 includes a lattice layer 21 including a plurality of honeycomb cells having a hollow, and a skin layer positioned on at least one surface of the lattice layer.

The grid layer 21 includes a honeycomb cell having a plurality of hexagonal cross-section-shaped hollows as shown in FIG. 1 described above. The diameter of the honeycomb cell may vary depending on physical properties required for the artificial marble 100, but may satisfy, for example, 3 mm to 28 mm.

The hollow may be opened up and down based on the thickness direction of the lattice layer 21. The hollow may be an empty space not filled with a separate material. When the hollow is maintained as an empty space, it is advantageous to reduce the weight of the artificial marble 100.

On the other hand, in one embodiment, the lattice layer 21 is made of a material having a specific gravity lower than the above-described filler. Specifically, the portion of the lattice layer 21 except for the hollow may be made of a material including polypropylene, polystyrene, polyphenylene, polyamide, polycarbonate, or a combination thereof. The materials may exhibit a specific gravity of about 0.5 g/cm ³ to about 1.4 g/cm ³ .

In addition to maintaining the hollow in the lattice layer 21 as an empty space, the material itself constituting the lattice layer 21 is composed of a material having a lower specific gravity than the filler, thereby providing a lightweight artificial marble 100. have.

In one embodiment, the skin layer is a layer in direct contact with the acrylic artificial marble body. In one embodiment, the skin layers 22 and 23 may be located on opposite sides of the lattice layer 21, respectively.

In one embodiment, each of the skin layers 22 and 23 located on both sides of the grid layer 21 facing each other so that the aforementioned hollow is not filled by the composition for forming an acrylic artificial marble body, the grid layer 21 May be covering both sides of each other. Accordingly, even if the acrylic artificial marble body 10 is applied to the honeycomb core 20 and formed in a curing method, the hollow in the grid layer 21 can be maintained as an empty bar, thereby reducing the weight of the artificial marble 100 Is advantageous to

On the other hand, in FIG. 2, although the skin layers 22 and 23 in the form of being located on both sides facing each other of the lattice layer 21 are disclosed, the skin layers are not necessarily limited to such a positional relationship. Likewise, it may be formed to cover at least a part of at least one surface of the lattice layer 21.

In one embodiment, the material forming the skin layers 22 and 23 may be the same material as the material constituting the above-described grid layer 21, or may be made of different materials. Examples of the materials constituting the skin layers 22 and 23 include polypropylene, polystyrene, polyphenylene, polyamide, polycarbonate, glass fiber, or a combination thereof.

For example, when the skin layers 22 and 23 are made of the above materials, the surface of the skin layers 22 and 23 that are in direct contact with the acrylic artificial marble body 10 has a size of several tens of nanometers to tens of micrometers. A number of microfibers may be protruding. That is, the skin layers 22 and 23 according to one embodiment may include a plurality of microfibers protruding from the surface. The microfiber may vary depending on the material, for example, polymer fiber, glass fiber, or a combination thereof.

In one embodiment, the protruding plurality of microfibers may be intertwined with each other. For example, a plurality of microfibers may be entangled with each other so that the surfaces of the skin layers 22 and 23 exhibit a nonwoven shape. Therefore, in the process of applying the composition for forming the artificial marble body, the composition for forming the artificial marble body penetrates into the space between the microfibers entangled in the shape of the non-woven fabric and is in close contact with the microfibers, and through the subsequent curing process, the acrylic artificial marble At the interface between the body 10 and the skin layer 22. 23, it is possible to physically and firmly bond.

In general, artificial marble in the form of plywood has a laminated structure in which a metal honeycomb core is attached using an adhesive layer on a thin artificial marble plate surface. Particularly, in the case of a metal honeycomb core (for example, an aluminum honeycomb core), since the surface of the polymer honeycomb core is smooth, it is inevitable to introduce a separate adhesive layer to secure adhesion to the artificial marble plate. However, since the adhesive layer is easily separated from the artificial marble slab when a temperature applied to the thermoforming process is applied, it is difficult to apply thermoforming to such a plywood artificial marble.

On the other hand, in the case of the artificial marble 100 according to one embodiment, the composition for forming the artificial marble body at the interface between the aforementioned skin layers 22 and 23 and the acrylic artificial marble body 10 described above is between a plurality of microfibers. It is possible to improve the interfacial adhesion by penetrating into the space, and it can exhibit excellent adhesive properties without introducing a separate adhesive and/or adhesive layer to the interface.

On the other hand, when the lattice layer 21 and the skin layers 22 and 23 are composed of the above-mentioned materials, the honeycomb core 20 has excellent flexibility due to the above-described materials. Therefore, it may be advantageous for the thermoforming of the artificial marble 100 including the same.

In one embodiment, the honeycomb core 20 may vary depending on the target artificial marble 100 thickness, for example, may have a thickness of 3 mm to 30 mm. On the other hand, for example, when the thickness of the artificial marble 100 should have a thickness of about 10 mm to 12 mm, the honeycomb core 20 may have a thickness of 3 mm to 6 mm, for example.

The artificial marble 100 according to an embodiment may have a flat plate shape as illustrated in FIGS. 1 to 2, but is not limited thereto. For example, the artificial marble 100 may be processed to have various shapes according to the result of thermoforming.

3 is a cross-sectional view showing an example of processing of artificial marble according to an embodiment

The artificial marble 100 described in FIG. 1 described above may be processed to have an additional curved shape through an additional processing process, such as the artificial marble 100 ′ of FIG. 3. The processing may be performed through a thermoforming process. For example, as the thermoforming process, a method of heating a plate-shaped artificial marble 100 and then fixing the heated artificial marble 100 to a mold having a curved shape may be used. However, the specific thermoforming process is not necessarily limited to the above method, and various known thermoforming methods may be used.

Meanwhile, the acrylic artificial marble body 10' and honeycomb core 20' constituting the artificial marble 100' processed to have a curved shape may be bent to have a curved shape, and the processed artificial marble body The skin layers 22' and 23' directly contacting (10') and the honeycomb core 20' positioned therebetween may also be bent.

That is, since the artificial marble 100 ′ of FIG. 3 is obtained by thermoforming the artificial marble 100 having the above-described flat plate shape, the acrylic artificial marble body 10 in the process of manufacturing the artificial marble 100 having the first flat plate shape The honeycomb core 20 having a flat plate shape integrated with the By thermoforming together, the final shape of the honeycomb core 20' is bent to have a curved shape.

Even if the artificial marble 100' has a curved shape, the aforementioned skin layers 22 and 23 and the acrylic artificial marble body 10 between the artificial marble body 10' and the honeycomb core 20' The physical bonds between the interfaces can still remain solid. Accordingly, like the artificial marble 100 having the above-described flat plate shape, the artificial marble 100 ′ having a curved surface shape may have problems such as separation of layers or slippage.

As described above, the artificial marble 100 and 100' includes a honeycomb core 20 and 20' inside, and thus can be reduced in weight and separately formed by integrally forming the acrylic artificial marble bodies 10 and 10'. Since there is no need for an adhesive layer, it can exhibit excellent thermoforming properties. Therefore, the above-described artificial marble (100, 100') is a field requiring artificial marble of various shapes, for example, interior/exterior walls of buildings, tops of countertops/sinks, or various building materials such as flooring materials such as living/lobby. It can be widely applied.

Hereinafter, the present invention will be described in more detail through examples and comparative examples, but the following examples and comparative examples are for the purpose of description and are not intended to limit the invention.

실시예 Example

First, a honeycomb core having a size of 3.5 mm thick, 100 mm wide, and 150 mm long is prepared. The honeycomb core has a honeycomb cell diameter of 3.0 mm and includes a lattice layer made of polypropylene and a polypropylene skin layer covering both the top and bottom of the lattice layer (ThermHex, Polypropylene Honeycomb).

Meanwhile, a composition for forming an artificial marble body is prepared separately.

Specifically, 100 parts by weight of an acrylic resin syrup made by dissolving polymethylmethacrylate in methylmethacrylate, 0.7 parts by weight of trimethylpropane trimethacrylate (Miwon), 0.5 parts by weight of calcium hydroxide (UBE), normal dodecyl Mercaptan (n-Dodecyl mercaptane, CHEVRON PHILLIPS CHEMICALS) 0.5 parts by weight, antifoaming agent (BYK-Chemie, A 515) 0.4 parts by weight, dispersant (BYK-Chemie, W 980) 0.1 parts by weight, silane coupling agent (gudam社, WD-70) 0.45 parts by weight and 1.4 parts by weight of pigment were added and stirred, and then 200 parts by weight of aluminum hydroxide (chalco Shandong Co.) was added, followed by sufficient stirring. The completely stirred mixture is defoamed in vacuum and stirred by adding 1.5 parts by weight of an initiator (Dongsung Hichem Co., Ltd., Chemex MOM) to obtain a composition for forming an artificial marble body.

Subsequently, a molded PVA film is laid on the mold, and the prepared artificial marble body forming composition is first coated thereon, and the prepared honeycomb core is disposed, and then the prepared artificial marble body forming composition is second coated and the upper release PVA film is covered. Then, it was cured in an oven at 80° C. for 30 minutes. Thereafter, the upper/lower mold release PVA film is removed, and both sides are processed to have a thickness of 12 mm, thereby obtaining artificial marble according to an embodiment.

비교예 Comparative example

An artificial marble according to a comparative example is obtained through the same method as the above-described example, except that only the composition for forming the artificial marble body without the honeycomb core is applied and cured to produce the artificial marble.

평가: 인조 대리석의 열성형성 Evaluation: Thermoforming of artificial marble

Each of the artificial marbles according to the above-described examples and comparative examples was cut into standards of 210 mm in length, 40 mm in width, and 12 mm in thickness, respectively, to prepare specimens for evaluation of thermoformability. The prepared specimens were left in an oven at 150° C. for 30 minutes, and then fixed to a mold (curvature: 70R) of a steel material having a curved shape and cooled at room temperature.

Subsequently, for the specimens for evaluation of thermoforming completely cooled, the weight of each specimen, whether or not cracking of the artificial marble surface occurred, and whether or not the adhesion between the honeycomb core and the artificial marble body was maintained are shown in Table 1 below.

	실시예Example	비교예Comparative example
중량weight	34.817 g34.817 g	55.356 g55.356 g
표면 갈라짐Surface crack	없음none	없음none
접착 유지 여부Maintain adhesion	OO	--

Referring to Table 1, it can be seen that the artificial marble of the embodiment containing the honeycomb core therein has a lower weight compared to the comparative example that does not include the honeycomb core, and the adhesion between the honeycomb core and the artificial marble body is maintained even after thermoforming. It can be confirmed that it is maintained.

Therefore, from the results of Table 1, the artificial marble according to one embodiment can be reduced in weight as described above, which can solve the transport and design constraints, as well as the excellent thermoforming characteristics of artificial marble of various shapes required It can be seen that it can be widely applied to.

Although the present invention has been described through preferred embodiments as described above, the present invention is not limited to this, and the present invention shows that various modifications and variations are possible without departing from the concept and scope of the following claims. Those in the field of technology to which they belong will readily understand.

(Explanation of codes)

10: acrylic artificial marble body 20: honeycomb core

21: grid layer 22, 23: skin layer

Claims

Acrylic artificial marble body containing a filler; And

A honeycomb core positioned inside the acrylic artificial marble body and having a specific gravity lower than that of the filler;

It includes,

The acrylic artificial marble body is integrally formed, artificial marble.
In claim 1,

The acrylic artificial marble body surrounds the honeycomb core so that the surface of the honeycomb core is not exposed, artificial marble.
In claim 1 or 2,

The filler is artificial marble, including aluminum hydroxide, magnesium hydroxide, calcium carbonate, talc, or a combination thereof.
In any one of claims 1 to 3,

The acrylic artificial marble body is obtained by curing the composition for forming an acrylic artificial marble body including the filler and acrylic resin syrup, artificial marble.
In claim 4,

The acrylic resin syrup comprises an acrylic monomer and a polymer of the acrylic monomer, artificial marble.
In claim 4 or 5,

The composition for forming the acrylic artificial marble body further includes an initiator, a crosslinking agent, a coupling agent, a surfactant, a reaction accelerator, an antistatic agent, an antibacterial agent, an antifoaming agent, a dispersing agent, a molecular weight modifier, an ultraviolet absorber, a colorant, or a combination thereof. .
In any one of claims 1 to 6,

The honeycomb core

A grid layer comprising a plurality of honeycomb cells having a hollow, and

Artificial marble comprising a skin layer located on at least one side of the cell grid layer.
In claim 7,

The honeycomb cell has a diameter of 3 mm to 28 mm, artificial marble.
In claim 7 or 8,

The lattice layer comprises polypropylene, polystyrene, polyphenylene, polyamide, polycarbonate or a combination thereof, artificial marble.
In any one of claims 7 to 9,

The skin layer is located on both sides of the grid layer facing each other, artificial marble.
In claim 10,

The skin layer covers both sides of the grid layer facing each other so that the hollow is not filled, artificial marble.
In any one of claims 7 to 11,

The skin layer is in contact with the acrylic artificial marble body, artificial marble.
In any one of claims 7 to 12,

The skin layer comprises polypropylene, polystyrene, polyphenylene, polyamide, polycarbonate, glass fiber or a combination thereof, artificial marble.
In claim 13,

The skin layer includes a plurality of microfibers protruding from the surface,

The plurality of microfibers are intertwined, artificial marble.
In any one of claims 1 to 14,

The honeycomb core has a thickness of 3 mm to 6 mm, artificial marble.
In any one of claims 1 to 15,

The artificial marble has a flat plate shape or a curved surface, artificial marble.