Functional interior and exterior architectural panel using natural artificial marble

Abstract

The present invention relates to a functional architectural interior / exterior material panel using natural artificial marble, comprising: a base board; a natural artificial marble layer laminated on one side of the base board; a corrugated board coated with a gypsum composition disposed on the other side of the base board; and a ceramic board or vermiculite board disposed on the other side of the corrugated board; wherein the natural artificial marble layer is formed by hardening a slurry comprising 30 to 40 weight% aluminum hydroxide and 300 to 400 weight% of a mixed aggregate containing 20 to 30 weight% illite and 40 to 60 weight% natural stone powder, based on 100 weight parts of a diluted binder solution.

Description

Technology Field

[0001] The present invention relates to a functional architectural interior / exterior panel using natural artificial marble, and more specifically, to a functional architectural interior / exterior panel in which a layer of natural artificial marble is laminated on one side of a base board and a composite laminate of a corrugated board coated with a gypsum composition and a ceramic board or vermiculite board is laminated on the other side, thereby securing lightweightness and structural strength while simultaneously improving thermal insulation, sound insulation, and fire resistance performance. Background Technology

[0003] Interior and exterior building materials must simultaneously satisfy various functional requirements, such as thermal insulation, soundproofing, and fire resistance, in addition to structural stability. In particular, with the recent strengthening of energy conservation and fire safety standards, there is an increasing demand for lightweight, multi-functional composite building panels.

[0004] Conventionally, cement boards, gypsum boards, metal panels, or synthetic resin-based panels have been widely used as interior and exterior building materials. However, each of these existing materials has the following limitations.

[0005] For example, while gypsum boards and cement boards offer relatively excellent fire resistance, they are vulnerable to impact, have limited sound absorption, and suffer from insufficient thermal insulation. Additionally, metal panels possess superior structural strength but have the disadvantage of low thermal insulation performance due to high thermal conductivity, requiring the addition of separate insulation materials.

[0006] On the other hand, while architectural interior materials utilizing artificial marble can provide excellent appearance and durability, they generally have issues such as generating toxic gases in the event of a fire or limitations in ensuring flame-retardant performance because they are typically manufactured using a resin-based process. Additionally, as they are often formed from a single material structure, it is difficult to simultaneously satisfy both thermal insulation and soundproofing performance.

[0007] In addition, structures with internal air layers have been proposed to reduce weight, but their actual application in construction has been limited due to issues such as reduced structural strength and interlayer delamination.

[0008] Therefore, there is a need to develop functional architectural interior / exterior panels with a new structure that can secure structural strength while maintaining lightweight properties, and simultaneously improve thermal insulation, sound insulation, and fire resistance performance in a balanced manner. Prior art literature

[0010] Republic of Korea Registered Patent No. 1954062 The problem to be solved

[0011] The present invention has been devised in consideration of the above-mentioned problems, and the first objective of the present invention is to provide a functional architectural interior / exterior panel using natural artificial marble that can secure structural strength while maintaining lightness by applying a structure in which a base board is used as a central substrate and a natural artificial marble layer, a corrugated board coated with a gypsum composition, and a ceramic board or a vermiculite board are composite laminated.

[0013] The second objective of the present invention is to provide a functional architectural interior / exterior panel using natural artificial marble that can simultaneously improve thermal insulation, sound insulation, and fire resistance performance through a natural artificial marble layer containing a high content of natural stone powder, an air layer structure of corrugated cardboard, and an inorganic-based laminated structure. means of solving the problem

[0015] According to the features for achieving the above-mentioned purpose, the first invention relates to a functional architectural interior / exterior material panel using natural artificial marble, comprising: a base board; a natural artificial marble layer laminated on one side of the base board; a corrugated board coated with a gypsum composition disposed on the other side of the base board; and a ceramic board or vermiculite board disposed on the other side of the corrugated board; wherein the natural artificial marble layer is formed by hardening a slurry comprising 30 to 40 weight% aluminum hydroxide and 300 to 400 weight% of a mixed aggregate containing 20 to 30 weight% illite and 40 to 60 weight% natural stone powder, based on 100 weight parts of a diluted binder solution.

[0017] The second invention is characterized in that, in the first invention, the binder dilution solution comprises a water-soluble acrylic binder and a silica-based binder.

[0019] The third invention is characterized in that, in the second invention, the binder diluent comprises 10 to 40 parts by weight of an acrylic binder diluent mixed with 20 to 40 parts by weight of water and 50 to 90 parts by weight of a silica-based binder, wherein the binder diluent comprises 10 to 40 parts by weight of an acrylic binder diluent mixed with 100 parts by weight of a water-soluble acrylic binder.

[0021] The fourth invention is characterized in that, in the first invention, the corrugated cardboard forms a plurality of air layers by means of a corrugated shape structure.

[0023] The fifth invention is characterized in that, in the first invention, an adhesive layer is further formed between the base board and the corrugated cardboard.

[0025] The sixth invention is characterized in that, in the first invention, a printed layer having a color or pattern printed by transfer printing is formed on the natural artificial marble layer.

[0027] The seventh invention is characterized in that, in the first invention, the base board is a calcium silicate board or a magnesium board. Effects of the invention

[0029] The functional architectural interior / exterior panel using natural artificial marble according to the present invention has a laminated structure centered on a base board and an improved load distribution effect due to the corrugated structure of the cardboard, thereby enabling excellent structural strength while maintaining lightness.

[0030] In addition, heat transfer is effectively blocked by the multiple air layers formed by the corrugated structure of the cardboard and the inorganic structure of the vermiculite board or ceramic board, thereby ensuring excellent thermal insulation performance.

[0031] In addition, the combined effect of the sound wave reflection and path enhancement caused by the waveform structure of the corrugated cardboard and the sound wave absorption and scattering effects caused by the porous structure of the illite and vermiculite boards results in improved sound insulation and sound absorption performance.

[0032] In addition, the inorganic-based laminated structure consisting of a natural artificial marble layer containing aluminum hydroxide, a base board (calcium silicate board or magnesium board), a gypsum coating layer, and a ceramic board or vermiculite board suppresses combustion during a fire and minimizes the generation of toxic gases, thereby ensuring excellent fire resistance performance.

[0033] In addition, by applying a natural artificial marble layer containing a high content of natural stone powder, a texture and appearance comparable to natural marble can be achieved, and the aesthetics as an interior and exterior building material can be enhanced. Brief explanation of the drawing

[0035] FIG. 1 is a first conceptual diagram showing the laminated structure of a functional architectural interior / exterior material panel using natural artificial marble according to the present invention. FIG. 2 is a second conceptual diagram showing the laminated structure of a functional architectural interior / exterior material panel using natural artificial marble according to the present invention. Specific details for implementing the invention

[0036] The following objects, other objects, features, and advantages of the present invention will be easily understood through the following preferred embodiments associated with the accompanying drawings. However, the present invention is not limited to the embodiments described herein and may be embodied in other forms.

[0037] Rather, the embodiments introduced herein are provided to ensure that the disclosed content is thorough and complete, and to ensure that the spirit of the invention is sufficiently conveyed to those skilled in the art.

[0038] The embodiments described and illustrated herein also include complementary embodiments.

[0039] In this specification, the singular form includes the plural form unless specifically stated otherwise in the text. As used in this specification, 'comprise' and / or 'comprising' does not exclude the presence or addition of one or more other components to the mentioned component.

[0040] The present invention will be described in detail below with reference to the drawings. In describing the specific embodiments below, various specific details have been included to explain the invention more specifically and to aid in understanding. However, a reader with sufficient knowledge in the art to understand the invention will recognize that it can be used without these various specific details. In some cases, it is noted in advance that commonly known parts that are not significantly related to the invention have been omitted to prevent confusion in describing the invention.

[0042] FIG. 1 is a first conceptual diagram showing the laminated structure of a functional architectural interior / exterior material panel using natural artificial marble according to the present invention, and FIG. 2 is a second conceptual diagram showing the laminated structure of a functional architectural interior / exterior material panel using natural artificial marble according to the present invention.

[0044] The present invention relates to a functional architectural interior / exterior panel using natural artificial marble, which can simultaneously secure lightness and structural strength by using a base board as a substrate, laminating a layer of natural artificial marble on one side thereof, and simultaneously laminating a corrugated board coated with a gypsum composition on the other side, and a ceramic board or a vermiculite board.

[0046] The present invention provides a functional architectural interior / exterior panel using natural artificial marble, which is formed by applying a natural artificial marble layer formed by hardening a mixed aggregate containing aluminum hydroxide, illite, and natural stone powder in a slurry form together with a diluted binder solution, thereby realizing the texture of natural stone, and through a plurality of air layers formed by the corrugated shape structure of the corrugated cardboard and an inorganic-based laminated structure, thermal insulation performance, sound insulation performance, and fire resistance performance can be improved.

[0048] The term "natural artificial marble" of the present invention refers to artificial marble containing 40 weight percent or more of natural stone powder, which acts as a major component rather than a simple filler and substantially dominates the overall physical properties and appearance.

[0050] As shown in FIG. 1, the functional architectural interior / exterior material panel using natural artificial marble of the present invention may be composed of a base board (20), a natural artificial marble layer (10) laminated on one side of the base board (20), a corrugated board (30) coated with a gypsum composition disposed on the other side of the base board (20), and a ceramic board (40a) or vermiculite board (40b) disposed on the other side of the corrugated board (30).

[0052] The above base board (20) functions as a base for the panel, and either a calcium silicate board or a magnesium board may be selected and applied.

[0053] When the above base board (20) is a magnesium board, magnesium oxide and magnesium chloride are used as main raw materials, and high strength, fire resistance, and impact resistance can be secured at the same time as lightweightness.

[0054] In addition, if the base board (20) is a calcium silicate board, it is lightweight, has excellent dimensional stability and water resistance, and can provide mechanical strength suitable for use as an interior or exterior building material.

[0055] In particular, the above calcium silicate board is made of inorganic material and has the characteristic of not burning or generating toxic gases in the event of a fire, so it can contribute to securing semi-noncombustible or noncombustible performance required for the interior / exterior panel of the present invention.

[0056] In addition, the calcium silicate board has minimal expansion or contraction due to changes in temperature and humidity, so deformation is minimized even during long-term use, and it has excellent resistance to moisture, maintaining stable performance in indoor and outdoor environments, and can function as a structural support layer for panels by securing sufficient bending strength and compressive strength in the form of a plate.

[0057] The above-described base board (20) is applied as the central substrate layer of the panel in the present invention, and is configured such that a natural artificial marble layer (10) is laminated on one side and a corrugated board (30) coated with a gypsum composition is arranged on the other side.

[0059] The above natural artificial marble layer (10) can be formed by laminating a slurry, prepared by mixing a binder dilution solution containing a water-soluble acrylic binder and a silica-based binder with a mixed aggregate composed of aluminum hydroxide, illite, and natural stone powder, onto one surface of the base board (20) and then curing it.

[0060] This is an improvement on the method used to manufacture artificial marble panels presented by the applicant in Korean Registered Patent Publication No. 10-2700488 to optimize lamination with a base board.

[0061] The above binder dilution solution can be prepared by including a water-soluble acrylic binder and a silica-based binder, and can be formed by preparing an acrylic binder dilution solution by mixing 20 to 40 parts by weight of water with 100 parts by weight of a water-soluble acrylic binder, and then mixing 50 to 90 parts by weight of a silica-based binder with 10 to 40 parts by weight of the acrylic binder dilution solution.

[0062] The above silica-based binder may include any one of silica sol, tetraorthosilicate, or ethylsilicate, and may perform the role of providing flame retardancy along with functioning as a binder.

[0063] In addition, the above mixed aggregate includes aluminum hydroxide, illite, and natural stone powder, and may comprise 30 to 40 weight% of aluminum hydroxide, 20 to 30 weight% of illite, and 40 to 60 weight% of natural stone powder.

[0064] At this time, the aluminum hydroxide can provide flame-retardant performance by releasing moisture upon thermal decomposition to suppress flames.

[0065] If the content of the aluminum hydroxide is less than 30 weight%, it may be difficult to sufficiently secure the flame-retardant performance required by building material standards, and if it exceeds 40 weight%, the content of other aggregates may decrease relatively, which may lower the texture and mechanical strength of the natural artificial marble.

[0066] The above illite can perform the role of absorbing and scattering sound waves through its porous structure.

[0067] If the content of the illite is less than 20 weight%, the sound absorption effect is negligible, making it difficult to expect an improvement in functionality; if it exceeds 30 weight%, the viscosity of the slurry increases excessively, which reduces coating performance and may cause cracking after curing.

[0068] In addition, the above natural stone powder can perform the function of maintaining mechanical strength while realizing the texture and color of natural artificial marble.

[0069] If the content of the above natural stone powder is less than 40 weight%, it may be difficult to achieve a natural marble appearance, and if it exceeds 60 weight%, the bonding strength with the binder is reduced, which may result in surface damage or detachment during processing.

[0070] Meanwhile, the aluminum hydroxide has a particle size of 8 to 100 μm, and the illite and natural stone powder have a particle size of 50 to 500 μm.

[0071] This particle size range is intended to ensure the fluidity and dispersibility of the slurry to enable uniform coating, and to simultaneously ensure the density and mechanical strength of the artificial marble layer after curing.

[0072] In particular, if the particle size of the aluminum hydroxide is less than 8㎛, the slurry viscosity may increase excessively due to aggregation between particles, which may reduce coating performance, and if it exceeds 100㎛, surface roughness may increase and internal defects in the layer may occur.

[0073] In addition, if the particle size of the illite and natural stone powder is less than 50㎛, it is difficult to form micropores, which may limit the expression of sound absorption properties, and if it exceeds 500㎛, the bonding strength between particles is reduced, which may cause cracking or detachment after hardening.

[0074] The above binder diluent and mixed aggregate are mixed in a ratio of 300 to 400 parts by weight of mixed aggregate to 100 parts by weight of binder diluent to form a slurry. If the content of the mixed aggregate is less than 300 parts by weight, the viscosity of the slurry is low, making it difficult to maintain the shape after lamination. If it exceeds 400 parts by weight, mixing and coating become difficult, and internal pores may be formed unevenly. Therefore, it is preferable to limit the content to the above range.

[0075] The above slurry can be applied to the surface of the base board (20) and then cured to form a natural artificial marble layer (10).

[0076] In addition, the above slurry can be applied to a uniform thickness using a blade and can form a dense surface layer by curing at room temperature.

[0077] In addition, the above natural artificial marble layer (10) can be polished to a glossy surface through a sanding process as needed.

[0079] The above corrugated cardboard (30) is structured to be placed on the other side of the base board (20).

[0080] The above corrugated cardboard (30) has a structure formed only of corrugations (corrugated shape), and due to such corrugated structure, a continuous air layer is formed inside the corrugated cardboard (30), and the air layer acts as an air layer with low thermal conductivity, so it can function as an insulating layer that suppresses heat transfer between the outside and the inside.

[0081] In addition, the corrugated cardboard (30) can improve sound insulation performance by increasing the path of sound waves and inducing reflection through a waveform structure, and can provide a sound absorption effect by attenuating some sound energy.

[0082] Meanwhile, a gypsum composition is coated on the surface of the corrugated cardboard (30). The gypsum composition is applied along the corrugated surface, and some of it penetrates into the interior and hardens, thereby reinforcing the strength of the corrugated structure and supplementing the flame retardancy of the organic corrugated cardboard, thereby improving the fire resistance performance of the entire panel.

[0083] In addition, the above gypsum composition can form an inorganic film after hardening to perform the function of improving the bonding stability between the corrugated board and the subsequently laminated ceramic board or vermiculite board.

[0084] The corrugation height, corrugation spacing, and thickness of the corrugated cardboard (30) can be appropriately set according to the required thermal insulation performance, mechanical strength, and overall thickness of the panel, but are not limited thereto.

[0085] Meanwhile, an adhesive layer (AD) may be further formed between the base board (20) and the corrugated cardboard (30).

[0086] The adhesive layer (AD) serves to improve the bonding strength between the base board (20) and the corrugated cardboard (30), thereby ensuring the integrity of the laminated structure.

[0087] The adhesive layer (AD) may be formed by including one or more of an acrylic adhesive, a urethane adhesive, an epoxy adhesive, or an inorganic adhesive, and the application method may include roll coating, spray coating, or a compression method after application.

[0088] In particular, the adhesive layer (AD) can be bonded by applying pressure after coating the entire surface of the corrugated cardboard, thereby enabling a stable bonding state while maintaining the corrugated structure.

[0089] In addition, the adhesive layer (AD) can secure sufficient adhesive strength after curing, thereby preventing interlayer delamination even under temperature changes or external loads, and can perform the role of improving the durability of the panel.

[0090] Meanwhile, the base board (20) is lightweight and has excellent processability, but has the problem of being brittle and easily broken. Accordingly, corrugated cardboard (30) can compensate for the brittleness of the entire panel.

[0092] On the other side of the corrugated cardboard (30), a ceramic board (40a) or a vermiculite board (40b) may be additionally placed through an adhesive layer (AD) to improve fire resistance or further increase sound absorption efficiency.

[0093] The ceramic board (40a) above is a non-metallic inorganic plate made by firing or combining inorganic raw materials, such as silica and alumina, at high temperatures. It has excellent high-temperature stability, excellent non-combustibility performance that prevents deformation or burning in the event of a fire, and can maintain its shape even at high temperatures.

[0094] Furthermore, due to its excellent chemical resistance, it is resistant to chemicals such as acids and alkalis and does not corrode; it also exhibits minimal mold growth or decay even when exposed to moisture. Additionally, it displays high surface hardness, providing excellent wear resistance and superior resistance to external scratches.

[0095] In addition, instead of a conventional ceramic board (40a), a vermiculite board (40b) disclosed by the applicant in Korean Registered Patent Publication No. 10-2918879 may be used as the ceramic board (40a).

[0096] The above vermiculite board (40b) has a porous structure, so it can improve sound absorption performance by absorbing and scattering sound waves, and as an inorganic material, it has excellent non-combustibility and does not generate toxic gases in the event of a fire, so it can improve fire resistance performance.

[0097] In addition, the vermiculite board (40b) has a lightweight nature due to its internal porous structure and low thermal conductivity, which can also contribute to improved thermal insulation performance.

[0099] Meanwhile, as shown in FIG. 2, various visual effects may be achieved by optionally applying ink on a natural artificial marble layer (10) using a transfer printing method to form a printed layer (50) containing various colors or patterns.

[0100] The above-mentioned printed layer (50) may be formed over the entire natural artificial marble layer (10) or only on a part thereof. Additionally, when the above-mentioned printed layer (50) is formed, a protective layer may be added by coating with a resin composition to protect the printed surface.

[0102] To evaluate the performance of the functional architectural interior / exterior panel using natural artificial marble of the present invention, a prototype was manufactured as follows.

[0103] [Example 1]

[0104] In this embodiment, an architectural interior / exterior panel with a basic structure comprising a natural artificial marble layer, a base board (using a calcium silicate board), and a vermiculite board was manufactured.

[0105] Specifically, a slurry of a binder dilution solution and mixed aggregate mixed in a weight ratio of 1:3 was applied to one side of a base board with a thickness of 5T to form an artificial marble layer with a thickness of about 1.5T, and a vermiculite board was placed on the other side of the base board to manufacture an interior / exterior building material panel.

[0106] -test-

[0107] The test method is in accordance with Article 24, Subparagraphs 1 and 2 of the Ministry of Land, Infrastructure and Transport Notification No. 2023-24, 'Standards for Quality Recognition and Management of Building Materials, etc.' The test environment is a temperature of 15 to 30℃ and a humidity of 20 to 80%RH.

[0108] Semi-noncombustible performance test results Test items Test results Judgment criteria 1 time 2nd time 3 times heat release rate Total heat released (MJ / ㎡) 5.7 6.2 6.3 <8 Time(s) when the heat release rate continuously exceeds 200 kW / m² 0 0 0 <10 Presence or absence of fire hazard factors in the test specimen No issues No issues No issues There won't be Gas toxicity Average time to stop behavior in test white rats (minutes:seconds) 14:49 13:30 - >9:00

[0109] As a result of the test, the heat release rate test results pursuant to Article 24, Subparagraph 1 of the Ministry of Land, Infrastructure and Transport Notification No. 2023-24 and the gas toxicity test results pursuant to Article 24, Subparagraph 2 of the Ministry of Land, Infrastructure and Transport Notification No. 2023-24 were found to be satisfactory, indicating that the material exhibits semi-noncombustible characteristics suitable for use as a building material. In addition, the results of the sound absorption performance evaluation commissioned to the Korea Testing & Research Institute are shown in Table 2. The test method was in accordance with KS F 2805:2014 (Method for measuring sound absorption performance using the reverberation chamber method). The test environment was a temperature of 19.5℃ and a humidity of 49.0% R.,H. at the start and end.

[0110] 1 / 3 octave band center frequency (Hz) Sound absorption coefficient α s 100 0.25 125 0.38 160 0.46 200 0.04 250 0.04 315 0.38 400 0.37 500 0.37 630 0.32 800 0.36 1,000 0.38 1,250 0.38 1,600 0.41 2,000 0.41 2,500 0.38 3,150 0.38 4,000 0.37 5,000 0.40

[0111] It was confirmed from the sound absorption performance evaluation results that it exhibits high sound absorption performance.

[0112] Meanwhile, the architectural interior / exterior panel according to the present invention is characterized by additionally forming a corrugated board coated with a gypsum composition between a base board and a vermiculite board in addition to the basic structure above.

[0113] Such corrugated cardboard improves sound insulation performance by increasing the propagation path of sound waves and inducing reflection through its waveform structure, and can provide a sound absorption effect by attenuating some sound energy.

[0114] Accordingly, the present invention can further improve the overall sound absorption performance by expanding the attenuation path of sound waves and increasing energy dissipation through the addition of corrugated cardboard, in addition to the sound absorption performance secured from the basic structure above.

[0116] The embodiments described in this specification and the configurations illustrated in the drawings are merely the most preferred embodiments of the present invention and do not represent all of the technical ideas of the present invention; therefore, it should be understood that various equivalents and modifications that can replace them may exist at the time of filing this application. Explanation of the symbols

[0118] 10: Natural artificial marble layer 20: Baseboard 30: Cardboard 40a: Ceramic board 40b: Vermiculite board 50: Print layer AD: Adhesive layer

Claims

Claim 1 A functional architectural interior / exterior panel using natural artificial marble comprises: a base board (20); a natural artificial marble layer (10) laminated on one side of the base board (20); a corrugated board (30) coated with a gypsum composition disposed on the other side of the base board (20); and a ceramic board (40a) or vermiculite board (40b) disposed on the other side of the corrugated board (30); wherein the natural artificial marble layer (10) is formed by hardening a slurry comprising 30 to 40 weight% of aluminum hydroxide and 300 to 400 weight% of a mixed aggregate containing 20 to 30 weight% of illite and 40 to 60 weight% of natural stone powder, based on 100 weight parts of a diluted binder solution. Claim 2 A functional architectural interior / exterior panel using natural artificial marble, characterized in that, in claim 1, the binder dilution solution comprises a water-soluble acrylic binder and a silica-based binder. Claim 3 A functional architectural interior / exterior panel using natural artificial marble, characterized in that, in paragraph 2, the binder diluent comprises 10 to 40 parts by weight of an acrylic binder diluent obtained by mixing 20 to 40 parts by weight of water with 100 parts by weight of a water-soluble acrylic binder, and 50 to 90 parts by weight of a silica-based binder. Claim 4 In claim 1, the above corrugated cardboard (30) is characterized by forming a plurality of air layers by a corrugated shape structure, a functional architectural interior / exterior panel using natural artificial marble. Claim 5 A functional architectural interior / exterior panel using natural artificial marble, characterized in that, in claim 1, an adhesive layer (AD) is further formed between the base board (20) and the corrugated board (30). Claim 6 A functional architectural interior / exterior material panel using natural artificial marble, characterized in that, in claim 1, a printed layer (50) with a color or pattern printed by transfer printing is formed on the natural artificial marble layer (10). Claim 7 A functional architectural interior / exterior panel using natural artificial marble, characterized in that, in claim 1, the base board (20) is a calcium silicate board or a magnesium board.

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