Artificial marble composition and production method for artificial marble using same

Patent metadata

Field	Value
Publication number	US-10766814-B2
Application number	US-201615762049-A
Country	US
Kind code	B2
Filing date	Nov 29, 2016
Priority date	Dec 1, 2015
Publication date	Sep 8, 2020
Grant date	Sep 8, 2020

Abstract

Disclosed are an artificial marble composition having a natural marble texture, and a method for producing artificial marble using the same. The artificial marble composition according to the present invention comprises: a first resin mixture; and a second resin mixture which is added to the first resin mixture and has a viscosity different from the first resin mixture, wherein each of the first and second resin mixtures comprises a base resin and an inorganic filler, and wherein the second resin mixture further comprises a thixotropic agent.

First claim

The invention claimed is:

1. An artificial marble composition comprising:
a first resin mixture; and
a second resin mixture added to the first resin mixture,
wherein a viscosity of the second resin mixture is different from a viscosity of the first resin mixture,
wherein each of the first and second resin mixtures comprises:
a base resin;
an inorganic filler;
a chip, wherein an amount of the chip ranges from 10 parts by weight to 100 parts by weight based on 100 parts by weight of the base resin; and
a catalyst, wherein the catalyst is an organic amine or an organic metal salt, and wherein an amount of the catalyst is 1 part by weight or less based on 100 parts by weight of the base resin,

wherein the first resin mixture and the second resin mixture are mixed with each other, and a weight ratio between the first resin mixture and the second resin mixture ranges from 1:1 to 10:1, and
wherein the second resin mixture further comprises a thixotropic agent, and wherein an amount of the thixotropic agent ranges from 0.5 part by weight to 3.0 parts by weight based on 100 parts by weight of the second resin mixture.

2. The artificial marble composition of claim 1 , wherein the first resin mixture includes 100 to 300 parts by weight of the inorganic filler based on 100 parts by weight of the base resin, and
the second resin mixture includes 100 to 300 parts by weight of the inorganic filler based on 100 parts by weight of the base resin.

3. The artificial marble composition of claim 1 , wherein the base resin comprises:
a polyacrylic resin, a polyester-based resin or a polystyrene-based resin, wherein an amount of the polyacrylic resin, the polyester-based resin or the polystyrene-based resin ranges from 20 parts by weight to 70 parts by weight based on 100 parts by weight of the base resin;
an acrylic monomer, an ester-based monomer or a styrene-based monomer, wherein an amount of the acrylic monomer, the ester-based monomer or the styrene-based monomer ranges from 30 parts by weight to 80 parts by weight based on 100 parts by weight of the base resin; and
a polyfunctional monomer, wherein an amount of the polyfunctional monomer ranges from 0.1 part by weight to 5 parts by weight based on 100 parts by weight of the base resin.

4. The artificial marble composition of claim 1 , wherein the inorganic filler has an average particle size of 1 to 100 μm and includes at least one of calcium carbonate, aluminum hydroxide, silica, alumina, magnesium hydroxide, and calcium aluminate.

5. The artificial marble composition of claim 1 , wherein each of the first and second resin mixtures further comprises an initiator, and wherein an amount of the initiator ranges from 0.1 part by weight to 1 part by weight based on 100 parts by weight of the base resin.

6. The artificial marble composition of claim 1 , wherein the chip is any one of an acrylic chip, an epoxy-based chip, a styrene-based chip, and a polyester-based chip.

7. The artificial marble composition of claim 5 , wherein the initiator includes at least one selected from the group consisting of tertiary butylcyclohexyl peroxydicarbonate, benzoyl peroxide, dicumyl peroxide, butyl hydroperoxide, cumyl hydroperoxide, t-butyl peroxymaleic acid, t-butyl hydroperoxide, acetyl peroxide, lauroyl peroxide, azobisisobutyronitrile, and azobisdimethylvaleronitrile.

8. The artificial marble composition of claim 1 , wherein the thixotropic agent includes at least one selected from an inorganic-based thixotropic agent including synthetic fine silica-based, bentonite-based, and very fine precipitated calcium carbonate, a composite-based thixotropic agent including organic bentonite-based and surface-treated calcium carbonate-based, and an organic-based thixotropic agent including urea-based, metal stone gum-based, hydrogenated castor oil, polyamide wax, polyethylene oxide-based, vegetable oil-based, polymeric oil-based, flaxseed polymeric oil, and a fatty acid dimer.

Assignees

• Lg Hausys Ltd

Inventors

• Nam Hae-Rim
• Yue Seong-Hoon
• Park Hwan-Seok
• Kim Jang-Soon
• Song Yea-Ri
• Kim Yu-Jun
• Park Min-Kyung

Classifications

• C04B2111/82

  Coloured materials · CPC title

• C04B2111/545

  Artificial marble · CPC title

• C04B26/04 Primary

  obtained by reactions only involving carbon-to-carbon unsaturated bonds · CPC title

• B29C67/243 Primary

  for making articles of definite length · CPC title

• B29C67/244

  by vibrating the composition before or during moulding · CPC title