Artificial marble composition and production method for artificial marble using same

Patent metadata

Field	Value
Publication number	US-2018282215-A1
Application number	US-201615762049-A
Country	US
Kind code	A1
Filing date	Nov 29, 2016
Priority date	Dec 1, 2015
Publication date	Oct 4, 2018
Grant date	—

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

1 . An artificial marble composition comprising:
a first resin mixture; and a second resin mixture added to the first resin mixture and having a viscosity different from that of the first resin mixture, wherein each of the first and second resin mixtures includes a base resin and an inorganic filler, and a thixotropic agent is further added to 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 thixotropic agent has an amount of 0.5 to 3.0 parts by weight based on 100 parts by weight of the second resin mixture.

4 . The artificial marble composition of claim 1 , wherein the base resin includes 20 to 70 parts by weight of a polyacrylic resin, a polyester-based resin or a polystyrene-based resin, 30 to 80 parts by weight of an acrylic monomer, an ester-based monomer or a styrene-based monomer, and 0.1 to 5 parts by weight of a polyfunctional monomer.

5 . 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.

6 . The artificial marble composition of claim 1 , wherein each of the first and second resin mixtures further includes a chip to be added in an amount of 10 to 100 parts by weight, an initiator to be added in an amount of 0.1 to 1 part by weight, and a catalyst to be added in an amount of 1 part by weight or less, based on 100 parts by weight of the base resin.

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

8 . The artificial marble composition of claim 6 , 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.

9 . The artificial marble composition of claim 6 , wherein the catalyst is an organic amine or an organic metal salt.

10 . 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.

11 . The artificial marble composition of claim 1 , wherein the first and second resin mixtures were mixed at a weight ratio of 1:1 to 10:1.

12 . A production method for artificial marble comprising:
(a) putting and casting a first resin mixture including a base resin and an inorganic filler into a mold; (b) injecting or stacking a second resin mixture including a base resin, an inorganic filler, and a thixotropic agent into the mold into which the first resin mixture is cast; and (c) agitating the first and second resin mixtures with an agitator to form a pattern, followed by curing and sanding.

13 . A production method for artificial marble comprising:
(a) putting and casting a first resin mixture including a base resin and an inorganic filler into a mold while aligning a nozzle in which a second resin mixture including a base resin, an inorganic filler, and a thixotropic agent is stored on an upper part of the first resin mixture; (b) dropping the second resin mixture stored in the nozzle onto the first resin mixture to form a pattern, followed by curing and sanding.

14 . (canceled)

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

• C04B24/283

  Polyesters · CPC title

• C04B22/066

  Magnesia; Magnesium hydroxide · CPC title

• B29C67/244

  by vibrating the composition before or during moulding · CPC title

• C04B26/04 Primary

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

• B44F9/04

  of stone surfaces, e.g. marble · CPC title