U.S. patent application number 13/012904 was filed with the patent office on 2011-05-19 for composite solid surface article containing ocher.
This patent application is currently assigned to CHEIL INDUSTRIES INC.. Invention is credited to Dong Choon CHUNG, Eung Seo PARK, Do Choon RHA.
Application Number | 20110118402 13/012904 |
Document ID | / |
Family ID | 36578156 |
Filed Date | 2011-05-19 |
United States Patent
Application |
20110118402 |
Kind Code |
A1 |
CHUNG; Dong Choon ; et
al. |
May 19, 2011 |
Composite Solid Surface Article Containing Ocher
Abstract
A composition for artificial marble includes (a) about 100 parts
by weight of an acrylic resin; (b) about 1 to about 30 parts by
weight of an ocher powder having a particle size of about 1 to
about 50 .mu.m; (c) about 100 to about 200 parts by weight of an
inorganic filler; (d) about 0.1 to about 10 parts by weight of
cross-linking agent; and (e) about 0.1 to about 10 parts by weight
of a polymerization initiator.
Inventors: |
CHUNG; Dong Choon;
(Yeosu-si, KR) ; RHA; Do Choon; (Seoul, KR)
; PARK; Eung Seo; (Yeosu-si, KR) |
Assignee: |
CHEIL INDUSTRIES INC.
Gumi-si
KR
|
Family ID: |
36578156 |
Appl. No.: |
13/012904 |
Filed: |
January 25, 2011 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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11759381 |
Jun 7, 2007 |
7875668 |
|
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13012904 |
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PCT/KR2005/004213 |
Dec 9, 2005 |
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11759381 |
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Current U.S.
Class: |
524/431 ;
264/299; 524/445 |
Current CPC
Class: |
C08K 3/013 20180101;
C04B 26/06 20130101; C08K 3/013 20180101; C08K 3/01 20180101; C04B
2111/545 20130101; C04B 14/36 20130101; C04B 26/06 20130101; C04B
26/06 20130101; C08K 3/01 20180101; C04B 40/0028 20130101; C04B
14/04 20130101; C04B 14/06 20130101; C04B 14/304 20130101; C04B
14/04 20130101; C04B 14/28 20130101; C04B 14/285 20130101; C08L
33/06 20130101; C04B 16/04 20130101; C04B 14/303 20130101; C04B
40/0028 20130101; C08L 33/06 20130101 |
Class at
Publication: |
524/431 ;
524/445; 264/299 |
International
Class: |
C08K 3/34 20060101
C08K003/34; C08K 3/22 20060101 C08K003/22; B28B 1/14 20060101
B28B001/14 |
Foreign Application Data
Date |
Code |
Application Number |
Dec 9, 2004 |
KR |
10-2004-0103495 |
Claims
1. A composite solid surface article comprising: about 100 parts by
weight of an acrylic resin; and about 1 to about 30 parts by weight
of loess or ocher powder having an average particle size of about 1
to about 50 .mu.m.
2. The composite solid surface article of claim 1, wherein the
article comprises a substantially smooth surface with a viewable
pattern formed by one or more ingredients of the composite solid
surface article, the viewable pattern comprising at least part of
the loess or ocher powder.
3. The composite solid surface article of claim 1, wherein the
acrylic resin comprises a mixture of a polyacrylate and an acrylic
monomer.
4. The composite solid surface article of claim 1, wherein the
article has a flexural strength of at least about 670 kgf/cm.sup.2
as measured in accordance with ASTM 790.
5. The composite solid surface article of claim 1, wherein the
article has a flexural strength of at least about 680 kgf/cm.sup.2
as measured in accordance with ASTM 790.
6. The composite solid surface article of claim 1, wherein the
article has an impact strength of at least about 1.4 kgcm/cm as
measured in accordance with ASTM D-256 at 23.degree. C.
7. The composite solid surface article of claim 1, wherein the
article has an impact strength of at least about 1.6 kgcm/cm as
measured in accordance with ASTM D-256 at 23.degree. C.
8. The composite solid surface article of claim 1, comprising about
1 to about 30 parts by weight of loess powder having an average
particle size of about 1 to about 50 .mu.m.
9. A structure comprising the composite solid surface article of
claim 1.
10. The structure of claim 9, wherein the structure is selected
from the group consisting of countertops, sinks, tables, bathtubs,
walls, and buildings.
11. The structure of claim 9, wherein the article comprises about 1
to about 30 parts by weight of loess powder having an average
particle size of about 1 to about 50 .mu.m.
12. The structure of claim 9, wherein the article comprises a
substantially smooth surface with a viewable pattern formed by one
or more ingredients of the composite solid surface article, the
viewable pattern comprising at least part of the loess or ocher
powder.
13. The structure of claim 9, wherein the acrylic resin comprises a
mixture of a polyacrylate and an acrylic monomer.
14. The structure of claim 9, wherein the article has a flexural
strength of at least about 670 kgf/cm.sup.2 as measured in
accordance with ASTM 790.
15. The structure of claim 9, wherein the article has a flexural
strength of at least about 680 kgf/cm.sup.2 as measured in
accordance with ASTM 790.
16. The structure of claim 9, wherein the article has an impact
strength of at least about 1.4 kgcm/cm as measured in accordance
with ASTM D-256 at 23.degree. C.
17. The structure of claim 9, wherein the article has an impact
strength of at least about 1.6 kgcm/cm as measured in accordance
with ASTM D-256 at 23.degree. C.
18. A method of making a composite solid surface article,
comprising: mixing about 100 parts by weight of an acrylic resin
with about 1 to about 30 parts by weight of loess or ocher powder
having an average particle size of about 1 to about 50 .mu.m to
form an article forming mixture; molding the article forming
mixture into a shape; and curing the shaped article forming mixture
to form the composite solid surface article.
19. The method of claim 18, wherein the mixing step comprises
mixing about 100 parts by weight of an acrylic resin with about 1
to about 30 parts by weight of ocher powder having an average
particle size of about 1 to about 50 .mu.m to form an article
forming mixture.
20. The method of claim 18, wherein the article comprises a
substantially smooth surface with a viewable pattern formed by one
or more ingredients of the composite solid surface article, the
viewable pattern comprising at least part of the loess or ocher
powder.
21. The method of claim 18, wherein the acrylic resin comprises a
mixture of a polyacrylate and an acrylic monomer.
22. The method of claim 18, wherein the article has a flexural
strength of at least about 670 kgf/cm.sup.2 as measured in
accordance with ASTM 790.
23. The method of claim 18, wherein the article has an impact
strength of at least about 1.4 kgcm/cm as measured in accordance
with ASTM D-256 at 23.degree. C.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This non-provisional application is a divisional application
of U.S. Ser. No. 11/759,381, filed Jun. 7, 2007, which is hereby
incorporated by reference in its entirety and which is a
continuation-in-part application of PCT Application No.
PCT/KR2005/004213, filed Dec. 9, 2005, which designates the U.S.
and which is hereby incorporated by reference in its entirety, and
claims priority from Korean Patent Application No. 10-2004-0103495,
filed Dec. 9, 2004, which is also hereby incorporated by reference
in its entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to a composition for composite
solid surface articles.
BACKGROUND OF THE INVENTION
[0003] Artificial marble is widely used as a building material.
Artificial marble is typically classified as acrylic artificial
marble or unsaturated polyester artificial marble. Acrylic
artificial marble is widely used because of its excellent
appearance, superior texture and good weatherability, as compared
to unsaturated polyester artificial marble. For example, acrylic
artificial marble is used as a material for kitchen, bath and other
countertops, sinks, dressing tables, bathtubs, wall materials,
interior articles, and the like.
[0004] Conventionally manufacturers of artificial marbles focus on
the production of a natural-stone-like texture. Accordingly, many
conventional marbles are only available with stone-like patterns.
Further, many conventional artificial marbles are not made with
eco-friendly material.
[0005] In general, ocher or loess has excellent detoxificant and
antibacterial effects. Accordingly ocher or loess is widely used in
food, cosmetic materials, cloth, and the like, and many popular
products include loess.
[0006] Further, ocher or loess can control temperature and
humidity. Accordingly, it can also act as an insulator and can
provide coolness in the summer and warmth in the winter. It has
also been used as a traditional building material in Korea.
[0007] Artificial marble including loess could be suitable for use
in interior building materials or various interior articles.
However, it can be difficult to produce such materials or articles
with both good mechanical strength and elegant ocher texture
because of the low compatibility of loess or ocher and acrylic
matrix resins and the resultant poor processability.
[0008] Korean Patent No. 272421 is directed to a method of
preparing artificial marble comprising preparing a loess molding
layer consisting of a mixture of loess and unsaturated polyester
resin, laminating a zeolite surface layer consisting of a mixture
of zeolite and unsaturated polyester resin onto the molding layer,
and curing the laminated layers. However, this method has poor
processability and the resulting artificial marble has poor
mechanical strength due to the high content of loess.
SUMMARY OF THE INVENTION
[0009] One aspect of the invention provides a composite solid
surface article including (a) about 100 parts by weight of an
acrylic resin; and (b) about 1 to about 30 parts by weight of ocher
or loess powder having a particle size of about 1 to about 50
.mu.m. The composite solid surface article of the invention can
further include (c) about 100 to about 200 parts by weight of an
inorganic filler; (d) about 0.1 to about 10 parts by weight of a
cross-linking agent; and (e) about 0.1 to about 10 parts by weight
of a polymerization initiator. In various embodiments the composite
solid surface article may also include about 0.1 to about 150 parts
by weight of marble chips.
[0010] The composite solid surface article of the invention can be
eco-friendly and further can have good mechanical strength and
unique ocher texture. Further, the composite solid surface article
of the invention can have a substantially smooth surface with a
viewable pattern formed by one or more ingredients thereof, wherein
the viewable pattern includes at least part of the loess or ocher
powder. Without being limited by any theory or explanation of the
invention, the inventors have found that adding loess to an acrylic
artificial composition in specific sizes and amounts can result in
a material having these and other desirable properties.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a photograph showing a surface pattern of a
composite solid surface article obtained in Example 1.
DETAILED DESCRIPTION OF THE INVENTION
[0012] The present invention now will be described more fully
hereinafter in the following detailed description of the invention,
in which some, but not all embodiments of the invention are
described. Indeed, this invention may be embodied in many different
forms and should not be construed as limited to the embodiments set
forth herein; rather, these embodiments are provided so that this
disclosure will satisfy applicable legal requirements.
[0013] Composite solid surface articles in accordance with the
invention can include (a) about 100 parts by weight of an acrylic
resin; and (b) about 1 to about 30 parts by weight of ocher or
loess powder having a particle size of about 1 to about 50 .mu.m.
Composite solid surface articles of the invention can further
include (c) about 100 to about 200 parts by weight of an inorganic
filler; (d) about 0.1 to about 10 parts by weight of a
cross-linking agent; and (e) about 0.1 to about 10 parts by weight
of a polymerization initiator.
(a) Acrylic Resin
[0014] Exemplary acrylic resins useful in the present invention can
include a mixture of one or more polyacrylate and one or more
acrylic monomers, for example, in the form of a resin syrup
including a mixture of acrylic monomer and its polymer,
polyacrylate.
[0015] Typical examples of the acrylic monomer can include without
limitation methacrylic acid, methacrylic acid esters such as methyl
methacrylate, ethyl methacrylate, isopropyl methacrylate, n-butyl
methacrylate, 2-ethylhexyl methacrylate, and the like, as well as
mixtures thereof.
[0016] In exemplary embodiments of the invention, the amount of
acrylic monomer can be equal to or more than about 65% by weight
and the amount of the polyacrylate can be equal to or less than
about 35% by weight, based on total weight of the acrylic resin
syrup.
(b) Ocher or Loess Powder
[0017] In exemplary embodiments of the invention, the average
particle size of the loess powder can range from about 1 to about
50 .mu.m, for example, from about 5 to about 40 .mu.m. Loess powder
having an average particle size of about 5 to about 40 .mu.m can
provide even higher mechanical properties in the resultant
article.
[0018] It can be difficult to control the process if the loess
powder has a particle size of less than about 1 .mu.m. The use of
loess powder having a particle size of more than about 50 .mu.m can
reduce the mechanical strength of the composite solid surface
article.
[0019] According to various exemplary embodiments of the invention,
the composite solid surface article can be eco-friendly and may
have a unique ocher texture or pattern on at least a portion of a
surface thereof, resulting from the use of the loess powder.
[0020] The amount of loess powder can range from about 1 to about
30 parts by weight, for example, about 5 to about 25 parts by
weight, per 100 parts by weight of acrylic resin.
[0021] If the amount of loess powder is more than about 30 parts by
weight, the mechanical strength of the composite solid surface
article can deteriorate. On the other hand, if the amount of loess
powder is less than about 1 part by weight, the composite solid
surface article prepared therefrom may not have a unique loessial
pattern.
(c) Inorganic Filler
[0022] Any inorganic filler well known in the art can be used.
Typical examples of the inorganic filler can include calcium
carbonate, aluminum hydroxide, silica, alumina, barium sulfate,
magnesium hydroxide, and the like, and mixtures thereof. The
inorganic filler of the present invention may have a particle size
of about 1 to about 100 .mu.m.
[0023] Aluminum hydroxide can advantageously impart a transparent
and elegant appearance to the artificial marble.
[0024] The amount of inorganic filler may range from about 100 to
about 200 parts by weight, for example, from about 120 to about 160
parts by weight, per 100 parts by weight of acrylic resin.
(d) Cross-Linking Agent
[0025] Exemplary cross-linking agents can include polyfunctional
(meth)acrylates. Examples of polyfunctional (meth)acrylates can
include ethylene glycol di(meth)acrylate, propylene glycol
di(meth)acrylate, glycerol tri(meth)acrylate, trimethylolpropane
tri(meth)acrylate, bisphenol A di(meth)acrylate, and the like, and
mixtures thereof.
[0026] The content of the cross-linking agent may range from about
0.1 to about 10 parts by weight, for example, from about 0.3 to
about 10 parts by weight, per 100 parts by weight of acrylic
resin.
(e) Polymerization Initiator
[0027] Exemplary polymerization initiators may include peroxides
such as benzoyl peroxide, lauroyl peroxide, butyl hydroperoxide,
cumene hydroperoxide, and the like, and azo compounds such as
azobisisobutylonitrile and the like, as well as mixtures
thereof.
[0028] The amount of polymerization initiator may range from about
0.1 to about 10 parts by weight, per 100 parts by weight of acrylic
resin.
(f) Marble Chips
[0029] In various embodiments, conventional artificial marble chips
with various colors may be optionally added. Typically, such marble
chips may have particle sizes from about 0.1 mm to about 5 mm. The
marble chips can be prepared using conventional methods. For
example, marble chips can be prepared by mixing about 100 parts by
weight of acrylic resin, about 120 to about 200 parts by weight of
an inorganic filler, about 0.1 to about 10 parts by weight of a
cross linking agent and about 0.1 to about 10 parts by weight of an
initiator, curing the mixture and pulverizing the cured
material.
[0030] In various embodiments, such marble chips may have sizes
from about 0.1 mm to about 1.0 mm.
[0031] The marble chips may be added in an amount of about 0 to
about 200 parts by weight, for example, about 0.1 to about 150
parts by weight, for example, about 0.1 to about 70 parts by
weight, per 100 parts by weight of acrylic resin to provide an
artificial marble with various patterns.
[0032] The artificial marble of the present invention can be
prepared using conventional methods. For example, all the
components and additives can be mixed together to obtain a slurry
of artificial marble. Then the slurry can be poured into a molding
cell and thereafter cured to form an artificial marble product.
[0033] The invention may be better understood by reference to the
following examples which are intended for the purpose of
illustration and are not to be construed as in any way limiting the
scope of the present invention, which is defined in the claims
appended hereto. In the following examples, all parts and
percentage are by weight unless otherwise indicated.
EXAMPLES
Example 1
[0034] 100 parts by weight of methyl methacrylate resin syrup
consisting of a mixture of 30% of poly methyl methacrylate and 70%
of methyl methacrylate, 20 parts by weight of loess powder having
an average particle size of 30 .mu.m, 155 parts by weight of a
mixture consisting of marble chips having particle sizes of 0.1 to
5 mm and aluminium hydroxide, 2 parts by weight of
trimethylolpropane tri(meth)acrylate and 2 parts by weight of
lauroyl peroxide are mixed, and stirred by a mixer to obtain a
mixed slurry. The mixed slurry is poured into a glass molding cell
having a size of 300 mm.times.600 mm.times.15 mm, and cured in an
oven at 45.degree. C., and then the mixed slurry is gradually
heated up to 100.degree. C. The cured mixed slurry is cooled to
room temperature to obtain a solid surface article in the form of a
flat plate. The resulting solid surface article has a unique and
refined ocher texture. A photograph of the resultant solid surface
article is shown in FIG. 1.
Example 2
[0035] Example 2 is prepared in the same manner as in Example 1
except that 10 parts by weight of loess powder having an average
particle size of 10 .mu.m is used.
Comparative Example 1
[0036] Comparative Example 1 is prepared in the same manner as in
Example 1 except that 50 parts by weight of loess powder is
used.
Comparative Example 2
[0037] Comparative Example 2 is prepared in the same manner as in
Example 2 except that loess powder having an average particle size
of 80 .mu.m is used.
[0038] The flexural strength and impact strength of the solid
surface articles of Examples 1-2 and Comparative Examples 1-2 are
determined by ASTM 790 and ASTM 256 respectively and are as
follows:
TABLE-US-00001 TABLE 1 Examples Comparative Examples 1 2 1 2
Flexural strength 680 672 489 320 (kgf/cm.sup.2) Izod impact
strength 1.6 1.4 0.8 1.0 (kg cm/cm)
[0039] As shown in Table 1, Comparative Example 1 demonstrates that
using an excessive amount of loess degrades flexural and impact
strength. Comparative Example 2 demonstrate that using excessively
large particles having a diameter of greater than 50 .mu.m also
degrades flexural and impact strength.
[0040] Many modifications and other embodiments of the invention
will come to mind to one skilled in the art to which this invention
pertains having the benefit of the teachings presented in the
foregoing descriptions. Therefore, it is to be understood that the
invention is not to be limited to the specific embodiments
disclosed and that modifications and other embodiments are intended
to be included within the scope of the appended claims. Although
specific terms are employed herein, they are used in a generic and
descriptive sense only and not for purposes of limitation, the
scope of the invention being defined in the claims.
* * * * *