Disco pad for manufacturing vein pattern of artificial marble, method for manufacturing artificial marble using same, and artificial marble

Abstract

The present invention relates to an artificial marble including a base part and a pattern part, wherein the pattern part includes a vein in which at least three straight lines are sequentially and directly connected or connected through a curved line, and the vein includes two or more connection parts in which an angle formed by a contact point in which two straight lines adjacent to each other are directly connected and the two straight lines, or an angle formed by a contact point between two extension lines of two straight lines adjacent to each other and the two straight lines is an obtuse angle.

Description

Disco pad for manufacturing vein patterns of artificial marble, method for manufacturing artificial marble using the same, and artificial marble

[0001] This application claims the benefit of the filing dates of Korean Patent Application No. 10-2023-0188631, filed with the Korean Intellectual Property Office on December 21, 2023, Korean Patent Application No. 10-2023-0188612, filed with the Korean Intellectual Property Office on December 21, 2023, Korean Patent Application No. 10-2024-0026454, filed with the Korean Intellectual Property Office on February 23, 2024, and Korean Patent Application No. 10-2024-0026416, filed with the Korean Intellectual Property Office on February 23, 2024, the entire contents of which are incorporated herein by reference.

[0002] The present invention relates to a disco pad for manufacturing vein patterns of artificial marble, a method for manufacturing artificial marble using the same, and artificial marble.

[0003] Engineered stone, also known as Easton, is an artificial marble used as an interior decoration material with a texture and feel similar to natural stone. Research has been conducted in the industry to enhance the aesthetics of artificial marble by improving its color and appearance. For example, Korean Patent No. 10-1270415 discloses an artificial marble with a variety of patterns and appearances using marble chips. Demand for engineered stone is steadily increasing for indoor flooring, wall decoration, and kitchen countertops, with products primarily imitating natural stone species such as granite and marble.

[0004] However, in recent years, the interior design market has seen a growing interest in natural stones like quartzite, which have more luxurious patterns. Reflecting this trend, the Easton industry is also making significant efforts to incorporate natural stone into its designs.

[0005] The present invention provides a disco pad for manufacturing vein patterns of artificial marble, a method for manufacturing artificial marble using the same, and artificial marble. More specifically, the present invention provides a disco pad for manufacturing vein patterns of artificial marble capable of implementing various natural stone patterns, a method for manufacturing artificial marble using the same, and artificial marble.

[0006] And, the present invention aims to provide artificial marble in which various natural stone patterns are implemented.

[0007] One embodiment of the present invention provides an artificial marble comprising a base portion and a pattern portion, wherein the pattern portion comprises a vane in which at least three straight lines are sequentially directly connected or connected through a curve, and wherein the vane comprises two or more connecting portions in which two adjacent straight lines are directly connected and an angle formed by the two straight lines; or in which the angle formed by the two extended lines of two adjacent straight lines and the two straight lines is an obtuse angle.

[0008] One embodiment of the present invention provides a disco pad for manufacturing a vein pattern of artificial marble, comprising a main body including a plurality of blade units including a rotation axis that rotates in one direction, a first inclined surface and a second inclined surface that are opposite to each other on both sides based on a plane perpendicular to the rotation axis, and a blade portion that is a line where the first inclined surface and the second inclined surface meet, and an inner angle of adjacent blade portions forms an obtuse angle.

[0009] One embodiment of the present invention provides a method for manufacturing artificial marble, comprising the steps of: forming a base layer in a plate shape by dispensing a base composition into a horizontally oriented mold; forming an intaglio pattern on the base layer using the disco pad for manufacturing a vein pattern of artificial marble of claim 1; injecting a vein pattern composition into the intaglio pattern; and performing a compression process and a heat treatment process to form artificial marble having a vein pattern.

[0010] According to one embodiment of the present invention, the blade portion of a disco pad for manufacturing a vein pattern of artificial marble is irregularly formed to form a natural vein pattern.

[0011] In addition, the veins of the artificial marble are provided unevenly rather than in a straight line, so that an artificial marble having a natural vein can be provided.

[0012] FIG. 1 is a drawing illustrating artificial marble according to one embodiment of the present invention.

[0013] Figure 2 is a front view schematically showing a disco pad for manufacturing artificial marble veins according to one embodiment of the present invention.

[0014] Figure 3 is a side view schematically showing a disco pad for manufacturing artificial marble veins according to one embodiment of the present invention.

[0015] Figure 4 is a flowchart illustrating a method for manufacturing artificial marble according to one embodiment of the present invention.

[0016] Fig. 5 is a photograph showing various forms of artificial marble according to an embodiment.

[0017] Fig. 6(a) is a photograph showing the artificial marble of Comparative Example 1, Fig. 6(b) is a photograph showing the artificial marble of Comparative Example 2, and Fig. 6(c) is a photograph showing the artificial marble of Comparative Example 3.

[0018] [Explanation of symbols]

[0019] 1: Disco pad for making veins

[0020] 100: Rotation axis

[0021] 200: Main body

[0022] 210: First slope

[0023] 220: Second slope

[0024] 230: Blade part

[0025] 10: Bass section

[0026] 20: Vein pattern

[0027] V: Bane

[0028] P: Pattern Department

[0029] This detailed description of the present invention is intended to fully explain the present invention to those skilled in the art. Throughout the specification, whenever a part is referred to as "comprising" a certain component or "characterizing" a certain structure or shape, unless specifically stated otherwise, this does not exclude other components or structures or shapes, but rather implies the inclusion of other components, structures, and shapes.

[0030] The present invention is susceptible to various modifications and embodiments. Therefore, specific embodiments are presented and described in detail in the detailed description. However, this is not intended to limit the scope of the invention to these embodiments, and it should be understood that all modifications, equivalents, and alternatives fall within the spirit and technical scope of the present invention.

[0031] Hereinafter, the present invention will be described in detail with reference to the drawings. However, the drawings are intended to illustrate the present invention, and the scope of the present invention is not limited by the drawings.

[0032]

[0033] The artificial marble according to the present invention comprises a base portion and a pattern portion (P), and the pattern portion (P) comprises a vane (V) in which at least three straight lines are sequentially directly connected or connected through curves, and the vane comprises two or more connecting portions in which the angle (θ) formed by the contact point between two adjacent straight lines and the angle (θ) formed by the two straight lines is an obtuse angle; or in which the angle (θ) formed by the contact point between two extension lines of two adjacent straight lines and the two straight lines is an obtuse angle.

[0034] The above obtuse angle may be between 130° and 178°. In this case, the obtuse angle refers to the interior angle of two adjacent straight lines or the interior angle between extension lines.

[0035] Since the pattern portion according to the present invention satisfies 130° to 178°, the pattern portion is not formed as a monotonous straight line, and the pattern portion does not deviate much from the straight line of 180°, so a natural pattern design can be implemented.

[0036] The total length of the pattern portion (P) may be 8 mm to 600 mm, and the length of the straight line forming the vane may be 2 mm to 30 mm. Preferably, the length of the straight line may be 2 mm to 25.5 mm.

[0037] And, the vane (V) may include two or more of the connecting portions within a length of 6 mm to 90 mm. Preferably, the vane (V) may include two or more of the connecting portions within a length of 6 mm to 76.5 mm. Preferably, the vane (V) may include two to fifteen of the connecting portions within a length of 6 mm to 90 mm.

[0038] The pattern portion (P) may include one or more vanes (V). For example, if the pattern portion includes one vane and the three straight lengths constituting the vane are 8 mm, 2 mm, and 3 mm, then two connection portions are included within a 13 mm length of the vane. If the pattern portion includes two vanes and the six straight lengths constituting the vane are 8 mm, 2 mm, 3 mm, 5 mm, 6 mm, and 6 mm, then five connection portions are included within a 30 mm length of the vane.

[0039] If the vane according to the present invention satisfies the length of the straight line, the problem of the straight line among the pattern portions not being clearly distinguished due to the length of the straight line forming the vane being short can be prevented, and the pattern portion can be prevented from becoming monotonous due to the length of the straight line forming the vane being long.

[0040] When the number of connecting parts of the vane according to the present invention is sufficient, the angle of the vane increases, preventing the pattern from being implemented in a monotonous form and enabling implementation of a pattern similar to a natural stone.

[0041] Among the two or more connecting portions of the above vane (V), one or two of the adjacent connecting portions may have different angles. Preferably, among the two or more connecting portions of the above vane (V), the angles of the adjacent connecting portions may be different from each other.

[0042] For example, when the vane includes two connecting portions, the angles of the two connecting portions are different from each other. When the vane includes three connecting portions, the three connecting portions are, in order, a first connecting portion, a second connecting portion, and a third connecting portion along the longitudinal direction of the vane. The three connecting portions may all have different angles, or the second connecting portion may have the same angle as the first connecting portion or the third connecting portion.

[0043] Since the above-mentioned vein and pattern portions include various connection angles and adjacent connection portions are provided at different angles from each other, the pattern portions are not monotonous and can provide an artificial marble with an aesthetic similar to that of natural stone when observed with the naked eye.

[0044] The length of the above-mentioned vane may be 5% to 30% longer than the length of the shortest line connecting the two ends located in the longitudinal direction of the above-mentioned vane. Preferably, the length of the above-mentioned vane may be 10% to 25% longer than the length of the shortest line, and more preferably, 10% to 20% longer.

[0045] By ensuring that the difference between the length of the above-mentioned vein and the length of the shortest line satisfies the above-mentioned range, the above-mentioned vein can be prevented from being excessively bent and forming an unnatural pattern.

[0046] The vane according to the present invention may have a straight pattern, a curved pattern, or a combination thereof.

[0047] Here, a straight line pattern refers to a pattern in which a straight line is connected without a break from one end of the vane to the other. In other words, a straight line pattern may be a form in which one or more straight lines are connected without a break from one end of the vane to the other. Therefore, when multiple straight lines are connected, a certain angle can be formed.

[0048] Furthermore, the presence or absence of a break in the vane and pattern portion can be determined based on the width of the straight or curved line that constitutes the vane. The width of the straight or curved line used as a reference is 0.5 mm. In other words, if the width of the straight or curved line is less than 0.5 mm, the vane is broken, and if the width of the straight or curved line is 0.5 mm or more, the vane is connected without a break area.

[0049] The above-described veins may intersect with each other. In one embodiment, a plurality of straight-line patterns may intersect with each other, a plurality of curved patterns may intersect with each other, or a straight-line pattern and a curved pattern may intersect with each other.

[0050] For example, when multiple straight line patterns intersect each other, they can be formed in the shape of Y, X, etc.

[0051] According to another embodiment, an artificial marble includes a base region and a pattern region including a vein pattern. The vein pattern includes a folded portion that is folded at least once, and an inner angle of the folded portion may form an obtuse angle.

[0052] Specifically, the vein pattern may include a plurality of unit patterns, and the unit patterns may include a plurality of pattern portions. That is, the plurality of pattern portions may be connected to each other and provided continuously, and the plurality of pattern portions may be bent to form a bent portion. In other words, adjacent pattern portions that are in contact with one end may form an obtuse angle, preferably 110° to 180°.

[0053] And, the vein pattern includes a plurality of bends, and the plurality of bends can include at least one different angle.

[0054] The length of the pattern portion may be 3 mm to 120 mm. Preferably, the length of the unit pattern may be 4 mm to 80 mm, and more preferably, 4 mm to 40 mm.

[0055] The vein pattern according to the present invention may be a straight line pattern, a curved line pattern, or a combination thereof.

[0056] Here, a straight line pattern refers to a pattern in which a straight line is connected without a break from one end of the vein pattern to the other. In other words, a straight line pattern may be a form in which one or more straight lines are connected without a break from one end of the vein pattern to the other. Therefore, when multiple straight lines are connected, a certain angle can be formed.

[0057] Additionally, the vein patterns may intersect with each other. In one embodiment, a plurality of straight-line patterns may intersect with each other, a plurality of curved patterns may intersect with each other, or a straight-line pattern and a curved pattern may intersect with each other.

[0058]

[0059] A method for manufacturing artificial marble according to one embodiment of the present invention comprises the steps of: forming a base portion in a plate shape by dispensing a base composition into a horizontally oriented mold; forming an intaglio pattern on the base portion using a disco pad for manufacturing a vein pattern of artificial marble, which will be described later; injecting a vein pattern composition into the intaglio pattern; and performing a compression process and a heat treatment process to form artificial marble having veins.

[0060] A method for manufacturing artificial marble according to one embodiment of the present invention includes a step of forming a base portion into a plate shape by spraying a base composition onto a horizontally oriented mold.

[0061] The mold may be a container having a predetermined shape so that the artificial marble composition discharged from the hopper can be contained in a predetermined shape. In particular, one embodiment of the present invention is different from the conventional process of manufacturing by vertically stacking different types of mixtures of natural quartz, unsaturated polyester liquid resin, and solid pigment, in which the mold is oriented horizontally to form a base portion in a plate shape.

[0062] The above base part can be formed by injecting a base composition into a plurality of hoppers controlled by a digital powder dispenser and then dispensing the base composition into a mold.

[0063] The above base composition may include a binder resin, inorganic particles and quartz powder.

[0064] The above binder resin is a resin containing an unsaturated polyester (UPE) polymer and a vinyl monomer.

[0065] The above binder resin can be manufactured by mixing and dispersing 0.4 to 2.5 parts by weight of a curing agent, 0.05 to 0.3 parts by weight of a catalyst, and 0.5 to 7 parts by weight of a coupling agent with respect to 100 parts by weight of an unsaturated polyester resin, and then curing.

[0066] The unsaturated polyester resin can be manufactured using a resin mixture comprising an unsaturated polyester polymer and a vinyl monomer. Preferably, the unsaturated polyester resin is manufactured using a composition comprising an unsaturated polyester polymer and a vinyl monomer in a weight ratio of 70:30 to 30:70. More preferably, the unsaturated polyester resin is manufactured using a composition comprising an unsaturated polyester polymer and a vinyl monomer in a weight ratio of 60:40 to 40:60.

[0067] Alternatively, the unsaturated polyester resin is manufactured using a composition comprising 40 to 60 wt% of an unsaturated polyester polymer and 40 to 60 wt% of a vinyl monomer.

[0068] The above unsaturated polyester resin may be a viscous solution, typically a solution in which an unsaturated polyester polymer is diluted within the vinyl monomer. Therefore, by satisfying the content of the vinyl monomer within the above-described range, the viscosity can be reduced, making the unsaturated polyester resin easier to handle. Furthermore, the vinyl monomer can cure the unsaturated polyester resin from a liquid to a solid through cross-linking of polyester molecular chains without producing byproducts. The weight average molecular weight of the unsaturated polyester resin is 1,000 g / mol to 10,000 g / mol.

[0069] The above unsaturated polyester polymer is not particularly limited, and for example, an unsaturated polyester polymer produced through a condensation reaction of a saturated or unsaturated dibasic acid and a polyhydric alcohol can be used. The saturated or unsaturated dibasic acid can be ortho-phthalic acid, isophthalic acid, maleic anhydride, citraconic acid, fumaric acid, itaconic acid, phthalic acid, phthalic anhydride, terephthalic acid, succinic acid, adipic acid, sebacic acid, or tetrahydrophthalic acid. In addition, as the polyhydric alcohol, ethylene glycol, diethylene glycol, triethylene glycol, propylene glycol, dipropylene glycol, tripropylene glycol, polypropylene glycol, 1,3-butylene glycol, hydrogenated bisphenol A, trimethylol propane monoaryl ether, neopentyl glycol, 2,2,4-trimethyl-1,3-pentadiol and / or glycerin can be used. In addition, monobasic acids such as acrylic acid, propionic acid or benzoic acid; or polybasic acids such as trimellitic acid or benzoic tetracarboxylic acid can be further used as needed.

[0070] As the type of the above vinyl monomer, an alkyl acrylate monomer or an aromatic vinyl monomer can be used, but considering the reactivity with the unsaturated polyester polymer, it is preferable to use an aromatic vinyl monomer. For example, as the above aromatic vinyl monomer, at least one selected from the group consisting of styrene, α-methylstyrene, p-methylstyrene, vinyl toluene, alkyl styrene substituted with an alkyl group having 1 to 3 carbon atoms, and styrene substituted with a halogen can be used, and a styrene monomer can be preferably used.

[0071] The above curing agent may be included for the curing reaction of the binder, and any curing agent used in the production of engineered stone may be used without particular limitation. The curing agent may be an organic peroxide compound or an azo compound. The organic peroxide compound may be one or two or more selected from among tert-butyl peroxybenzoate thermosetting agent (TBPB, Trigonox C, Akzo Nobel), diacyl peroxide, hydroperoxide, ketone peroxide, peroxyester, peroxyketal, dialkyl peroxide, alkyl perester, percarbonate, and peroxydicarbonate. Examples thereof include, but are not limited to, tert-butyl peroxybenzoate thermosetting agent, benzoyl peroxide, dicumyl peroxide, butyl hydroperoxide, cumyl hydroperoxide, methyl ethyl ketone peroxide, t-butyl peroxy maleate, t-butyl hydroperoxide, acetyl peroxide, lauroyl peroxide, t-butyl peroxy neodecanoate, or t-amyl peroxy 2-ethyl hexanoate.

[0072] In addition, the azo compound may be azobisisobutyronitrile, but is not necessarily limited thereto. The binder resin may include 0.4 to 2.5 parts by weight of a hardener based on 100 parts by weight of the unsaturated polyester resin. If the hardener is included in an amount less than the above range, it is difficult for the binder to harden, and if it is included in an amount exceeding the above range, discoloration of the binder may occur, and thus, it may be included within the above range.

[0073] The above catalyst may be included to promote hardening of the binder at low temperatures, and may be a catalyst used in the production of engineered stone, and is not particularly limited thereto, and may be one or more selected from metal soaps such as cobalt-based, vanadium-based, or manganese-based, tertiary amines, quaternary ammonium salts, and mercaptans. For example, a cobalt 6% catalyst (Hex-Cem, Borchers) may be used. The binder resin may include 0.05 to 0.3 parts by weight of the catalyst based on 100 parts by weight of the unsaturated polyester resin. If the catalyst is included in an amount less than the above range, hardening is not promoted, and if it is included in an amount exceeding the above range, discoloration of the binder may occur, and thus, it may be included within the above range.

[0074] The coupling agent may be included to enhance the bonding strength between the binder and natural mineral particles, and may be a silane-based or silicate-based agent. The binder resin may include 0.5 to 7 parts by weight of the coupling agent relative to 100 parts by weight of the unsaturated polyester resin. If the coupling agent is included in an amount below the above range, the bonding strength with the natural mineral particles decreases, and if it is included in an amount exceeding the above range, the unit price of raw materials increases, so it may be included within the above range.

[0075] The inorganic particles of the base composition of the present invention refer to inorganic particles having a particle size of 0.1 mm to 4.0 mm. The particle size can be measured using a Beckman Coulter LS 13 320 particle size analyzer.

[0076] The inorganic particles of the base composition of the present invention may be amorphous silica particles, glass particles, crystalline quartz particles, etc. In addition, the inorganic particles of the base composition may be at least one selected from the group consisting of amorphous silica particles, glass particles, and crystalline quartz particles. The inorganic particles may be amorphous silica particles or crystalline quartz particles, and in this case, the inorganic particles may be inorganic particles having a SiO2 content of 99.5 wt% to 100 wt%.

[0077] Preferably, the inorganic particles of the base composition of the present invention are amorphous silica particles, glass particles, and / or crystalline quartz particles having a SiO2 content of 99.5 wt% to 100 wt%. An artificial marble manufactured using amorphous silica particles or crystalline quartz particles having a SiO2 content of 99.5 wt% to 100 wt% as the inorganic particles of the base composition has higher hardness than an artificial marble manufactured using glass particles containing barium (Ba) ions within the particles. In addition, an artificial marble manufactured using amorphous silica particles or crystalline quartz particles having a SiO2 content of 99.5 wt% to 100 wt% as the inorganic particles of the base composition has higher hardness than an artificial marble manufactured using glass particles containing barium (Ba) ions within the particles.

[0078] The inorganic particles of the above base composition may be amorphous silica particles. The silica particles are a term commonly used in the field of artificial marble, and generally refer to SiO2-based inorganic particles having a high SiO2 content of 90 wt% or more and containing a small amount of other components such as minerals in addition to SiO2. The amorphous silica particles of the base composition of the present invention may be amorphous fused silica particles, and the amorphous silica particles of the base composition may also be referred to herein as highly transparent amorphous fused silica particles. The amorphous fused silica particles may be amorphous fused silica particles having a particle size of 0.1 mm to 4.0 mm, and further have a SiO2 content of 99.5 wt% to 100 wt%, preferably 99.6 wt% to 100 wt%, more preferably 99.7 wt% to 100 wt%, and an alumina content of 0.5 wt% or less, preferably 0.4 wt% or less, more preferably 0.3 wt% or less, and even more preferably 0.2 wt% or less. When the SiO2 content in the amorphous silica particles is 99.5 wt% or more, preferably 99.6 wt% or more, and more preferably 99.7 wt% or more, the transparency of the base portion of the artificial marble is further improved.

[0079] The SiO2 content of the silica particles and quartz particles of the present invention can be confirmed by quantitative analysis of the content using an XRF (X-Ray Fluorescence spectrometer). In addition, crystalline particles and amorphous particles can be confirmed using XRD (X-ray diffraction), and can generally be confirmed by measuring the particles after making them into pellets.

[0080] The inorganic particles of the base composition of the present invention may be crystalline quartz particles. The crystalline quartz particles of the base region of the present invention may also be referred to herein as highly transparent crystalline quartz particles.

[0081] At this time, the crystalline quartz particles of the base region may be highly transparent crystalline quartz particles having a particle size of 0.1 mm to 4.0 mm, and may also have a SiO2 content of 99.5 wt% to 100 wt%, preferably 99.6 wt% to 100 wt%, more preferably 99.7 wt% to 100 wt%, and an alumina content of 0.5 wt% or less, preferably 0.4 wt% or less, more preferably 0.3 wt% or less, and even more preferably 0.2 wt% or less.

[0082] If the SiO2 content in the crystalline quartz particles of the above base composition is less than 99.5 wt%, for example, 99.4 wt% or less, the transparency of the artificial marble decreases. Therefore, it is preferable that the crystalline quartz particles have a SiO2 content of 99.5 wt% or more.

[0083] In the present invention, quartz powder refers to quartz powder having a particle size of 0.1 mm or less. The particle size can be measured using a Beckman Coulter LS 13 320 particle size analyzer.

[0084] The quartz powder of the base composition of the present invention may also be referred to herein as a high-transparency crystalline quartz powder.

[0085] The quartz powder of the base composition of the present invention is a crystalline quartz powder, and is preferably a crystalline quartz powder having a SiO2 content of 99.5 wt% to 100 wt%. The quartz powder of the base composition may have a SiO2 content of 99.5 wt% to 100 wt%, preferably 99.6 wt% to 100 wt%, more preferably 99.7 wt% to 100 wt%, and an alumina content of 0.5 wt% or less, preferably 0.4 wt% or less, more preferably 0.3 wt% or less, and even more preferably 0.2 wt% or less.

[0086] The quartz powder of the above base composition preferably has an average SiO2 content of 99.5 wt% to 100 wt%, and an average alumina content of 0.5 wt% or less.

[0087] The SiO2 content of the quartz powder of the above base composition can be confirmed by quantitative analysis of the content using an XRF (X-Ray Fluorescence spectrometer). In this case, the content can generally be confirmed by making the powders into pellets and then measuring them.

[0088] Since the quartz powder of the above base composition has small particle size, self-scattering occurs. Therefore, in order to increase the internal transmittance of the base portion of the artificial marble, the base composition of the present invention may use crystalline quartz powder having a SiO2 content of 99.5 wt% or more. If the SiO2 content of the quartz powder is less than 99.5 wt%, the internal transmittance of the base region of the artificial marble is low, so that an artificial marble having relatively low transparency of the base portion can be manufactured.

[0089] The above base composition may include 500 to 700 parts by weight of inorganic particles and 200 to 400 parts by weight of quartz powder per 100 parts by weight of binder resin.

[0090] In addition, the base composition includes 500 to 700 parts by weight of inorganic particles and 200 to 400 parts by weight of quartz powder with respect to 100 parts by weight of binder resin, the binder resin includes an unsaturated polyester polymer and a styrene monomer at a ratio of 70:30 to 30:70, and the quartz powder may have a SiO2 content of 99.5 to 100 wt% and an alumina content of 0.5 wt% or less.

[0091] In one embodiment of the present invention, the step of forming a base portion into a plate shape by spraying a base composition onto a horizontally oriented mold may additionally include a compaction process of the base portion. The compaction process is a step of primarily pressing the powdered base composition, and can serve to create a certain gap to prevent the compound from collapsing or breaking during the subsequent step of forming an intaglio pattern. In particular, in order to form a vane having a thickness of 3 mm to 5 mm, it is preferable to perform the compaction process.

[0092] A method for manufacturing artificial marble according to one embodiment of the present invention includes a step of forming an engraved pattern on the base portion. The step of forming the engraved pattern on the base portion is characterized by using a disco pad for manufacturing a vein pattern of artificial marble according to the present invention.

[0093] Accordingly, the engraved pattern is formed in a zigzag shape, and the angle of the folded portion can be 130° to 178°.

[0094] In detail, the negative pattern is formed by a plurality of auxiliary negative portions by a single blade portion, and adjacent auxiliary negative portions can be bent at an angle of 130° to 178°. In addition, the length of the auxiliary negative portion can be 2 mm to 30 mm. Preferably, the length of the auxiliary negative portion can be 2 mm to 25.5 mm.

[0095] For example, the step of injecting the pattern composition described below may involve spraying the pattern composition onto the negative pattern. In this case, since the area where the pattern composition is sprayed is limited, if the length of the auxiliary negative pattern satisfies the above numerical range, the vein can appear continuously without a portion being cut in the middle.

[0096] In other words, if the length of the auxiliary negative portion is less than the above numerical range, the length of the auxiliary negative portion is short, and thus no veins appear on the surface of the artificial marble after the compression process and heat treatment process.

[0097] In addition, if the length of the auxiliary negative portion exceeds the above numerical range, an area in which the pattern composition is not injected may occur, and the vein may be formed in a form in which it is cut in the middle.

[0098] The step of forming the intaglio pattern may include a plurality of unit patterns, and the unit patterns may be formed spaced apart from each other, connected to each other, or formed by mixing unit patterns spaced apart from each other and connected unit patterns.

[0099] A unit pattern may be a pattern that does not repeat over a certain period. In one embodiment, the disco pad for manufacturing artificial marble veins may have blades with different angles. Accordingly, the pattern formed on the base as the disco pad rotates once may be a unit pattern.

[0100] For example, if the average diameter of the main body of the disco pad is 20 mm, the entire length of the blade may be 125 mm to 126 mm, and at this time, the length of the unit pattern may be 125 mm to 126 mm.

[0101] Alternatively, the length of the unit pattern may be 3 mm to 120 mm. Preferably, the length of the unit pattern may be 4 mm to 80 mm, and more preferably, 4 mm to 40 mm.

[0102] The depth of the above-mentioned engraved pattern may be 80% or less of the thickness of the above-mentioned base portion, 75% or less, or 50% or more.

[0103] If the depth of the engraved pattern exceeds 80% of the thickness of the base, the disco pad for manufacturing the vein may touch the lower floor during the process of forming the engraved pattern on the base, and the area of ​​the vein may become excessively large, making it difficult to completely dry the vein. In addition, if the depth of the engraved pattern is less than 50% of the thickness of the base, the vein may be removed during post-processing such as banding or cutting down of the manufactured artificial marble, which is not preferable.

[0104] A method for manufacturing artificial marble according to one embodiment of the present invention includes a step of injecting a vein pattern composition into the engraved pattern.

[0105] The above-mentioned vein composition may include a binder resin and a pigment. In addition, the vein composition may further include inorganic particles, quartz powder, and a monomer. For example, the monomer may be a styrene monomer.

[0106] The inorganic particles and quartz powder that may be further included in the above-mentioned vein composition may be applied to the contents of the inorganic particles and quartz powder of the above-mentioned base composition, so a detailed description thereof will be omitted.

[0107] The above pigment is preferably an inorganic pigment. The pigment may be any pigment commonly used in the production of artificial marble and is not particularly limited. For example, it may be TiO2, NiO·Sb2O3·20TiO2, Fe2O3, Fe3O4, etc.

[0108]

[0109] At this time, in order to manufacture veins having various colors, multiple vein compositions having pigments that can express each color applied can be used.

[0110] The mixing of the above-mentioned vein composition can be performed by a dry mixer or a wet mixer applied in a ceramic powder mixing process.

[0111] In one embodiment of the present invention, the step of injecting the vein composition into the engraved pattern may be performed by a powdering process or a spraying process of discharging the vein composition. By this process, the veins of the artificial marble can be implemented in various colors, and not only can thin and clear veins having one or more colors be formed adjacent to each other, but also natural flowing patterns, spreading patterns, etc., such as gradient colors, can be implemented. Accordingly, the veins according to one embodiment of the present invention may have two or more colors, gradient colors, or a combination thereof. In addition, the veins according to one embodiment of the present invention may include a straight line pattern, a curved line pattern, or a combination thereof.

[0112] In one embodiment of the present invention, after the step of injecting a vein pattern composition into the engraved pattern, a step of performing a compression process and a heat treatment process to form an artificial marble having a vein is included.

[0113] The above compression process and heat treatment process can utilize methods known in the art. For example, the above compression process can be performed in a range of 20,000 tons or more based on manufacturing a slab measuring 3,000 mm X 1,400 mm, but is not limited thereto.

[0114] The above heat treatment process may be applied at various temperature ranges depending on the type of binder resin, but is preferably performed at 90°C to 150°C. In addition, the above heat treatment process may be applied at various time ranges depending on the type and size of the polymer resin, but is preferably performed for 20 to 60 minutes.

[0115] After the above compression process and heat treatment process, a process of removing the mold, a post-processing process of cutting all sides of the artificial marble and then polishing the surface to make it smooth, etc. may be additionally sequentially included.

[0116]

[0117] A disco pad (1) for manufacturing artificial marble veins includes a rotation shaft (100) and a main body (200). In addition, the main body (200) includes a first inclined surface (210), a second inclined surface (220), and a blade portion (230).

[0118] The disco pad (1) according to the present invention refers to a configuration that forms an engraved pattern on the base, and may be used with other terms such as knife, knife, tool, etc.

[0119] The rotation axis (100) rotates the main body (200) and can be coupled with the main body (200). In addition, the rotation axis (100) can be coupled with the widest part of the main body (200). At this time, the width of the main body (200) means the distance between the ends at corresponding positions on both sides based on a cross-section perpendicular to the rotation axis (100).

[0120] The main body (200) may be provided with a plurality of first inclined surfaces (210) and second inclined surfaces (220) on each side based on a cross-section perpendicular to the rotation axis (100). The first inclined surface (210) and the second inclined surface (220) may become further apart from each other as they move toward the center of the main body (200) in a cross-section perpendicular to the rotation axis (100).

[0121] The first inclined plane (210) and the second inclined plane (220) may have different lengths from the adjacent first inclined plane (210) and second inclined plane (220), respectively. In this case, the lengths of the first inclined plane (210) and the second inclined plane (220) refer to the distance from the rotation axis (100) to the blade portion (230).

[0122] And, the first inclined surface (210) and the second inclined surface (220) forming one blade portion (230) may have the same or different lengths.

[0123] Accordingly, the blade portion (230) can form an obtuse angle with the adjacent blade portion (230). That is, two or three adjacent blade portions (230) can form an angle due to the adjustment of the lengths of the first inclined surface (210) and the second inclined surface (220).

[0124] Preferably, two or three adjacent blades (230) may be provided at an angle of 130° to 178°. More preferably, they may be provided at an angle of 135° to 177°.

[0125] And, the angle between adjacent blade portions (230) may be different by at least 1. In other words, since the main body portion (200) includes one or more blade portions (230), a plurality of angles may be formed between adjacent blade portions (230). And, the angles between the plurality of blade portions (230) may be different by at least 1.

[0126] For example, if the lengths of the first inclined plane (210) and the second inclined plane (220) forming one blade portion (230) are equal and the lengths of adjacent first inclined planes (210) are equal, the blade portion (230) forms an angle of 180°. When the angle of the blade portion (230) is 180°, the disco pad (1) can form the vane in a straight line shape or a zigzag shape with a long period, and therefore, there was a problem that the vane became monotonous.

[0127] In contrast, the disco pad (1) according to the present invention can form a vane in a zigzag shape with a short cycle by the angle of the blade portion (230), and therefore, it is possible to implement an irregular and unique pattern design in which the vane is not uniform or monotonous.

[0128] In addition, if the angle of the blade part (230) is less than 130°, there is a problem that the mixture remains on the blade part (230) and the shape of the vane becomes unclear.

[0129] The length of the blade portion (230) may be 2 mm to 30 mm. Preferably, the length of the blade portion (230) may be 2 mm to 25.5 mm.

[0130] The diameter of the main body (200) may be 20 mm to 80 mm. Preferably, the diameter of the main body (200) may be 60 mm to 80 mm. In this case, the diameter of the main body (200) refers to the distance from the rotation axis (100) to the circumference or outer surface of the main body (200). In other words, the diameter of the main body (200) refers to the length of the first inclined surface (210) or the second inclined surface (220).

[0131] That is, the main body (200) according to the present invention may include at least one diameter since the lengths of adjacent first inclined surfaces (210) are different, and the above numerical range means the average diameter of the main body (200).

[0132] The main body (200) may have a unit pattern whose length may be lengthened or shortened depending on its diameter. In this case, a unit pattern refers to a pattern without a repeated shape in a single pattern. In other words, when the main body (200) rotates once, a single unit pattern can be formed.

[0133] For example, if the average diameter of the main body (200) is 20 mm, the unit pattern length may be 125 mm, and if the average diameter of the main body (200) is 80 mm, the unit pattern length may be 502 mm. That is, if the average diameter of the main body (200) is large, the unit pattern length may increase.

[0134] The width of the main body (200) may be 10 mm to 70 mm. Preferably, the width of the main body (200) may be 10 mm to 60 mm, and more preferably, 20 mm to 60 mm.

[0135] Since the width and diameter of the main body (200) satisfy the above ranges, the width of the engraved pattern formed on the base by the main body (200) is not narrow and the depth is not shallow, so that the vein can appear clearly after the compression process and the heat treatment process.

[0136] In other words, if the width and diameter of the main body (200) are less than the above range, the width or depth of the engraved pattern may be narrow, resulting in a problem in which the vein does not appear after the compression process and heat treatment process.

[0137] In addition, if the width and diameter of the main body (200) exceed the above range, the width of the negative pattern may be too wide or the depth may be too deep, so that the pattern composition may not be sprayed on the part adjacent to the surface of the base part among the negative pattern parts, and thus a problem may occur in which a vein does not appear after the compression process and the heat treatment process.

[0138] The main body (200) may include a low-friction material. The low-friction material may include, for example, any one of polytetrafluoroethylene (PTfe), polyamide, graphite, acetol, and ultra-high molecular weight polyethylene (UHMW-PE), and preferably, the main body (200) may include ultra-high molecular weight polyethylene (UHMW-PE).

[0139] The main body (200) includes a low-friction material, thereby reducing friction with the base, and thus preventing the problem of the base part sticking to the main body (200) when forming an intaglio pattern, resulting in the intaglio pattern not being clearly formed.

[0140] And, after forming the negative pattern, smooth washing is achieved in the process of washing the main body (200), so that when forming the negative pattern with the disco pad (1) after washing, it can be implemented with reproducibility.

[0141] In addition, since the main body (200) includes ultra-high molecular weight polyethylene, the effect of enabling multiple use of the disco pad (1) can be generated due to the excellent properties of ultra-high molecular weight polyethylene, such as impact resistance, chemical resistance, and mechanical properties.

[0142]

[0143] Although the present invention has been described above with reference to preferred embodiments thereof, it will be understood by those skilled in the art that various modifications and changes may be made to the present invention without departing from the spirit and scope of the present invention as set forth in the claims below.

[0144]

[0145] Example

[0146] A disco pad having a blade angle of 135° to 177°, an average radius of 80 mm, and a blade length of 4 mm to 40 mm was used to form an engraved pattern with a depth of 20 mm and a width of 10 mm on the base.

[0147] Artificial marble was manufactured by spraying a vein composition onto an intaglio pattern, compressing, and heat-treating.

[0148] Comparative Example 1

[0149] An artificial marble was manufactured under the same conditions as in the example, except that a disco pad was used, which included a main body having a blade angle of 178° to 180° and a blade length of 120 mm to 122 mm.

[0150] Comparative Example 2

[0151] An artificial marble was manufactured under the same conditions as in the example, except that a disco pad was used, which included a main body having a blade angle of 80° to 100° and a blade length of 2 mm to 3 mm.

[0152] Comparative Example 3

[0153] Artificial marble was manufactured under the same conditions as in the example, except that a disco pad having an average radius of the main body of less than 20 mm was used.

[0154]

[0155] Referring to Fig. 6, in Comparative Example 1, the angle between adjacent blades was large, so the length of one blade was long, and therefore the vane was implemented regularly like a long curve, resulting in an unnatural problem.

[0156] In Comparative Example 2, the angle between adjacent blade parts was small, so the base part remained in the main body part at the bent part of the blade part, and a problem occurred in which the middle of the vane was cut and implemented discontinuously.

[0157] In Comparative Example 3, the average diameter of the main body was small, so the depth of the engraved pattern was shallow, resulting in a problem of reduced clarity of the vein.

[0158] In contrast, referring to FIG. 5, the veins of the artificial marble according to the embodiment are clear, continuous, and irregular, thus realizing a natural look like natural stone.

Claims

1. Includes base and pattern parts, The above pattern portion includes a vane in which at least three straight lines are sequentially connected directly or through curves, The above-mentioned vein is an artificial marble including two or more connecting portions, wherein the connecting portion is an obtuse angle formed by the point where two adjacent straight lines are directly connected and the angle formed by the two straight lines; or the connecting portion between two extended lines of two adjacent straight lines and the angle formed by the two straight lines.

2. An artificial marble according to claim 1, wherein the obtuse angle is 130° to 178°.

3. An artificial marble according to claim 1, wherein the vein includes two or more connecting portions within a length of 6 mm to 90 mm.

4. An artificial marble in which, in the third paragraph, the angles of adjacent connecting portions among the two or more connecting portions are different from each other.

5. An artificial marble according to claim 1, wherein the length of the vein is 10% to 20% longer than the length of the shortest line connecting the two ends located in the longitudinal direction of the vein.

6. A rotating axis that rotates in one direction and It includes a main body part including a plurality of first and second inclined planes facing each other on both sides with respect to a line perpendicular to the rotation axis, and a blade part which is a surface where the first and second inclined planes come into contact, A disco pad for manufacturing a vein pattern of artificial marble, wherein the adjacent blade portion forms an obtuse angle.

7. A disco pad for manufacturing a vein pattern of artificial marble, wherein the adjacent blade parts in the 6th paragraph form an angle of 110° to 180°.

8. In the 6th paragraph, the disco pad for manufacturing a vein pattern of artificial marble has a main body having a diameter of 20 mm to 80 mm.

9. A disco pad for manufacturing a vein pattern of artificial marble in the 6th paragraph, wherein the maximum widths of the first inclined surface and the second inclined surface are 10 mm to 70 mm.

10. A disco pad for manufacturing a vein pattern of artificial marble in the 6th paragraph, wherein the first inclined surface and the second inclined surface have different lengths from the adjacent first inclined surface and the second inclined surface, respectively.

11. A disco pad for manufacturing a vein pattern of artificial marble, wherein the length of the blade part in paragraph 6 is 3 mm to 120 mm.

12. A step of forming a base layer in a plate shape by spraying a base composition onto a horizontally oriented mold; A step of forming an engraved pattern on the base layer using a disco pad for manufacturing a vein pattern of artificial marble of Article 6; A step of injecting a vein pattern composition into the above-mentioned negative pattern; and A step of forming an artificial marble having a vein pattern by performing a compression process and a heat treatment process. A method for manufacturing artificial marble comprising:

13. A method for manufacturing artificial marble in clause 12, wherein the depth of the engraved pattern is 80% or less of the thickness of the base layer.

14. The artificial marble manufactured by the method for manufacturing artificial marble of Article 12 includes a pattern area including a base area and a vein pattern, An artificial marble wherein the above-mentioned vein baton includes a bent portion that is bent at least once, and the bent portion forms an obtuse angle.

15. In the 12th paragraph, the bending portion forms an angle of 110° to 180°, The above vein pattern includes multiple bends, An artificial marble wherein the plurality of bends include at least one different angle.

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