Composite material, method for its preparation and articles prepared therefrom

Abstract

The present disclosure relates to a composite material comprising predetermined amounts of a resin, a calcined clay, a filler and an additive. The composite material of the present disclosure exhibits improved stain resistance, mechanical strength, durability, and thermal stability. The present disclosure further relates to a method for the preparation of the composite material that is simple and economic. Still further, the present disclosure relates to articles prepared from the composite material that have improved, thermal resistance, mechanical strength and aesthetics.

Description

[0001] COMPOSITE MATERIAL, METHOD FOR ITS PREPARATION AND ARTICLES PREPARED THEREFROM FIELD

[0002] The present disclosure relates to a composite material and a method for its preparation.

[0003] DEFINITIONS

[0004] As used in the present disclosure, the following terms are generally intended to have the meaning as set forth below, except to the extent that the context in which they are used, indicate otherwise.

[0005] Calcined clay: The term “calcined clay” refers to clay that has been subjected to high-temperature treatment (calcination) to remove moisture and volatile substances.

[0006] Chamotte: The term “chamotte” refers to a type of calcined clay or fireclay that has been heated to high temperatures (1000 °C to 1400 °C) to remove moisture and transform it into a material with specific physical properties. The process of calcination makes chamotte highly resistant to heat and thermal shock.

[0007] BACKGROUND

[0008] The background information herein below relates to the present disclosure but is not necessarily prior art.

[0009] Natural and engineered stones, such as granite and quartz, find diverse applications including preparation of kitchen countertops, sinks, workstations; bathroom features, and the like. Granite is a natural stone formed from slow cooling of magma and is composed of quartz, feldspar, and mica, which has characteristic appearance and durability. Quartz is an engineered stone made from natural quartz crystals, resins, polymers, and pigments. Both granite and quartz find widespread application due to their durability and aesthetic appeal, however, they have certain drawbacks such as, quartz when exposed to high temperature can lead to cracks and discoloration. Further, granite is porous and requires regular resealing. Also, it is difficult to handle as it a heavy material.

[0010] Therefore, there is felt a need to provide a material that obviates the drawbacks mentioned hereinabove or at least provide an alternative solution.OBJECTS

[0011] Some of the objects of the present disclosure, which at least one embodiment herein satisfies, are as follows.

[0012] An object of the present disclosure is to ameliorate one or more problems of the background or to at least provide a useful alternative.

[0013] Another object of the present disclosure is to provide a composite material.

[0014] Yet another object of the present disclosure is to provide a composite material that has high mechanical strength, is capable of withstanding thermal shock, is resistant to cracking and is scratch resistant.

[0015] Still another object of the present disclosure is to provide a method for the preparation of a composite material.

[0016] Yet another object of the present disclosure is to provide articles prepared from a composite material.

[0017] Other objects and advantages of the present disclosure will be more apparent from the following description, which is not intended to limit the scope of the present disclosure. SUMMARY

[0018] In an aspect, the present disclosure relates to a composite material. The composite material comprises:

[0019] • a resin in an amount in the range of 15 mass% to 30 mass% with respect to the total mass of the composite material;

[0020] • a calcined clay in an amount in the range of 50 mass% to 80 mass% with respect to the total mass of the composite material;

[0021] • a filler in an amount in the range of 5 mass% to 20 mass% with respect to the total mass of the composite material; and

[0022] • an additive in an amount in the range of 0.1 mass% to 1 mass% with respect to the total mass of the composite material.

[0023] In an embodiment of the present disclosure, the resin is an acrylic resin.In an embodiment of the present disclosure, the calcined clay is at least one selected from the group consisting of metakaolin, montmorillonite, bentonite, kaolinite, palygorskite and chamotte.

[0024] In an embodiment of the present disclosure, the fdler is at least one selected from the group consisting of quartz, olivine, feldspar, pyroxene, mica, granite and ceramic.

[0025] In an embodiment of the present disclosure, the additive is at least one selected from the group consisting of a pigment, an oxidizing agent, a curing agent and a coupling agent.

[0026] In an embodiment of the present disclosure,

[0027] • the pigment is selected from the group consisting of tin oxide, titanium dioxide, iron oxide, cobalt oxide, cobalt carbonate, chromium oxide, vanadium pentoxide and cerium oxide;

[0028] • the oxidizing agent is selected from the group consisting of benzoyl peroxide (BPO), methyl ethyl ketone peroxide (MEKP) and dicumyl peroxide (DCP);

[0029] • the curing agent is selected from the group consisting of an azo compound, an acid anhydride and an amine; and

[0030] • the coupling agent is a silane coupling agent.

[0031] In another aspect, the present disclosure relates to a method for the preparation of a composite material. The method comprises the following steps:

[0032] a. mixing predetermined amounts of a calcined clay and a resin under stirring at a first predetermined speed to obtain a resultant mixture; and

[0033] b. adding predetermined amounts of a filler and an additive to the resultant mixture, followed by blending at a second predetermined speed to obtain the composite material.

[0034] In an embodiment of the present disclosure, the first predetermined speed is in the range of 200 rpm to 300 rpm.

[0035] In an embodiment of the present disclosure, the second predetermined speed is in the range of 50 rpm to 100 rpm.

[0036] In still another aspect, the present disclosure relates to an article produced by using a composite material, wherein the article is produced by casting the composite material in amould, followed by curing at a temperature in the range of 20 °C to 80 °C to obtain the article.

[0037] DETAILED DESCRIPTION

[0038] The present disclosure relates to a composite material, and a method for its preparation. The present disclosure further relates to articles prepared from the composite material.

[0039] Embodiments are provided so as to thoroughly and fully convey the scope of the present disclosure to the person skilled in the art. Numerous details are set forth, relating to specific components, and methods, to provide a complete understanding of embodiments of the present disclosure. It will be apparent to the person skilled in the art that the details provided in the embodiments should not be construed to limit the scope of the present disclosure. In some embodiments, well-known processes, well-known apparatus structures, and well-known techniques are not described in detail.

[0040] The terminology used, in the present disclosure, is only for the purpose of explaining a particular embodiment and such terminology shall not be considered to limit the scope of the present disclosure. As used in the present disclosure, the forms "a,” "an," and "the" may be intended to include the plural forms as well, unless the context clearly suggests otherwise. The terms "comprises," "comprising," “including,” and “having,” are open ended transitional phrases and therefore specify the presence of stated features, integers, steps, operations, elements, modules, units and / or components, but do not forbid the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof. The particular order of steps disclosed in the method and process of the present disclosure is not to be construed as necessarily requiring their performance as described or illustrated. It is also to be understood that additional or alternative steps may be employed. As used herein, the term "and / or" includes any and all combinations of one or more of the associated listed elements.

[0041] Granite is a natural stone formed from slow cooling of magma and is composed of quartz, feldspar, and mica, which has characteristic appearance and durability. Quartz is an engineered stone made from natural quartz crystals, resins, polymers, and pigments. Both granite and quartz find widespread application due to their durability and aesthetic appeal, however, they have certain drawbacks such as quartz when exposed to high temperature canlead to cracks and discoloration. Further, granite is porous and requires regular resealing; it is difficult to handle as it a heavy material; and is resource intensive.

[0042] The present disclosure provides a composite material, and a method for the preparation of the composite material. The present disclosure further provides articles prepared from the composite material.

[0043] In an aspect of the present disclosure, there is provided a composite material. The composite material comprises:

[0044] • a resin in an amount in the range of 15 mass% to 30 mass% with respect to the total mass of the composite material;

[0045] • a calcined clay in an amount in the range of 50 mass% to 80 mass% with respect to the total mass of the composite material;

[0046] • a filler in an amount in the range of 5 mass% to 20 mass% with respect to the total mass of the composite material; and

[0047] • an additive in an amount in the range of 0.1 mass% to 1 mass% with respect to the total mass of the composite material.

[0048] In an embodiment of the present disclosure, the resin is an acrylic resin.

[0049] In an embodiment of the present disclosure, the acrylic resin is selected from the group consisting of methyl methacrylate (MMA), MMA-Styrene copolymer, MMA-butyl acrylate copolymer and MMA-glycidyl methacrylate copolymer.

[0050] In an embodiment of the present disclosure, the calcined clay is at least one selected from the group consisting of metakaolin, montmorillonite, bentonite, kaolinite, palygorskite and chamotte.

[0051] In an exemplary embodiment of the present disclosure, the calcined clay is chamotte.

[0052] Chamotte is typically composed of alumina (AI2O3) and silica (SiCh), with other minerals present in smaller amounts, wherein alumina provides high melting point and thermal stability; and silica provides strength and resistance to thermal shock to chamotte. Other oxides, such as lime (CaO) and iron oxide (Fe2O3) are also present in small amounts in chamotte.Chamote is resistant to high temperature of up to 1600 °C or more, does not crack or lose its integrity under thermal cycling; has a low rate of thermal expansion; maintains its shape during heating or cooling cycles; is reasonably porous, which aids in insulation and thermal management; and has relatively high mechanical strength.

[0053] In an embodiment of the present disclosure, the chamote is a fused chamote.

[0054] Fused chamote is a high-performance refractory aggregate made by melting aluminosilicate materials (such as clay and alumina) to form synthetic mullite, resulting in a material with superior mechanical strength, thermal shock resistance, and low porosity.

[0055] In another embodiment of the present disclosure, the chamote is a natural chamote.

[0056] Natural chamote is a highly heat-resistant, calcined (fired) clay material, also known as grog or fireclay, used to make ceramics and refractories. It is produced by firing natural clays at high temperatures (1400 °C to 1600 °C) to remove water and organic mater, creating a stable, inert aggregate that reduces shrinkage, cracking, and deformation in high-temperature applications.

[0057] In an embodiment of the present disclosure, the filler is at least one selected from the group consisting of quartz, olivine, feldspar, pyroxene, mica, granite and ceramic. In an exemplary embodiment of the present disclosure, the filler is quartz.

[0058] In an embodiment of the present disclosure, the calcined clay is coated with the filler.

[0059] In an embodiment of the present disclosure, the filler is absent in the composite material. In an embodiment of the present disclosure, the additive is at least one selected from the group consisting of a pigment, an oxidizing agent, a curing agent and a coupling agent.

[0060] In an embodiment of the present disclosure, the composite material comprises a pigment to provide the resulting article with a desired color, shade and aesthetic appearance. The pigment is selected from the group consisting of an inorganic pigment, an organic pigment and a combination thereof.

[0061] In an embodiment of the present disclosure, the pigment is selected from the group consisting of tin oxide, titanium dioxide, iron oxide, cobalt oxide, cobalt carbonate, chromium oxide, vanadium pentoxide and cerium oxide.In an embodiment of the present disclosure, the pigment is present in an amount in the range of 0.1 mass% to 0.5 mass% with respect to the total mass of the composite material.

[0062] In an embodiment of the present disclosure, the oxidizing agent is at least one selected from the group consisting of is selected from benzoyl peroxide (BPO), methyl ethyl ketone peroxide (MEKP) and dicumyl peroxide (DCP).

[0063] In an embodiment of the present disclosure, the oxidizing agent is present in an amount in the range of 0.1 mass% to 0.5 mass% with respect to the total mass of the composite material. In an embodiment of the present disclosure, the curing agent is selected from the group consisting of an azo compound, an acid anhydride and an amine.

[0064] In an embodiment of the present disclosure, the azo compound is selected from the group consisting of azo-bis-isobutyronitrile, azo-bis-isobutyramide and azo-bis-cyanovaleric acid. In an embodiment of the present disclosure, the acid anhydride is selected from the group consisting of maleic anhydride, succinic anhydride, glutaric anhydride, hexahydrophthalic anhydride (HHPA), methyl hexahydrophthalic anhydride (MHHPA), phthalic anhydride, trimellitic anhydride, pyromellitic dianhydride, acetic anhydride and propionic anhydride. In an embodiment of the present disclosure, the amine is selected from the group consisting of ethylenediamine, diethylenetriamine, triethylenetetramine, tetraethylenepentamine, isophorone diamine, 4,4'-diaminodicyclohexylmethane, polyamide amines and polyether amines.

[0065] In an embodiment of the present disclosure, the coupling agent is a silane coupling agent. In an embodiment of the present disclosure, the silane coupling agent is selected from the group consisting of 3-methacryloxypropyltrimethoxysilane, 3 -aminopropyltriethoxy silane and 3 -glycidoxypropyltrimethoxy silane .

[0066] The composite material of the present disclosure has high mechanical strength, is capable of withstanding thermal shock, is resistant to cracking and is scratch resistant.

[0067] In another aspect of the present disclosure, there is provided a method for the preparation of a composite material. The method comprises the following steps:a. mixing predetermined amounts of a calcined clay and a resin under stirring at a first predetermined speed to obtain a resultant mixture; and

[0068] b. adding predetermined amounts of a filler and an additive to the resultant mixture, followed by blending at a second predetermined speed to obtain the composite material.

[0069] The method is described in detail.

[0070] In a first step, predetermined amounts of a calcined clay and a resin are mixed under stirring at a first predetermined speed to obtain a resultant mixture.

[0071] In an embodiment of the present disclosure, the resin is an acrylic resin.

[0072] In an embodiment of the present disclosure, the acrylic resin is selected from the group consisting of methyl methacrylate (MMA), MMA-Styrene copolymer, MMA-butyl acrylate copolymer and MMA-glycidyl methacrylate copolymer.

[0073] In an embodiment of the present disclosure, the predetermined amount of the resin is in the range of 15 mass% to 30 mass% with respect to the total mass of the composite material. In an embodiment of the present disclosure, the calcined clay is at least one selected from the group consisting of metakaolin, montmorillonite, bentonite, kaolinite, palygorskite and chamotte. In an exemplary embodiment of the present disclosure, the calcined clay is chamotte.

[0074] In an embodiment of the present disclosure, the predetermined amount of the calcined clay is in the range of 50 mass% to 80 mass% with respect to the total mass of the composite material.

[0075] In an embodiment of the present disclosure, the first predetermined speed is in the range of 200 rpm to 300 rpm.

[0076] In a second step, predetermined amounts of a filler and an additive are added to the resultant mixture, followed by blending at a second predetermined speed to obtain the composite material.

[0077] In an embodiment of the present disclosure, the predetermined amount of the filler is in the range of 5 mass% to 20 mass% with respect to the total mass of the composite material.In an embodiment of the present disclosure, the second predetermined speed is in the range of 50 rpm to 100 rpm.

[0078] In an embodiment of the present disclosure, the fdler is at least one selected from the group consisting of quartz, olivine, feldspar, pyroxene, mica, granite and ceramic. In an exemplary embodiment of the present disclosure, the fdler is quartz.

[0079] In an embodiment of the present disclosure, the quartz is in the form of granules.

[0080] In an embodiment of the present disclosure, the calcined clay is coated with the fdler.

[0081] In an embodiment of the present disclosure, the predetermined amount of the additive is in the range of 0.1 mass% to 1 mass% with respect to the total mass of the composite material. In an embodiment of the present disclosure, the additive is at least one selected from the group consisting of a pigment, an oxidizing agent, a curing agent and a coupling agent.

[0082] In an embodiment of the present disclosure, the pigment is dispersed homogeneously within the resin matrix prior to casting and curing.

[0083] In an embodiment of the present disclosure, the pigment is selected from the group consisting of tin oxide, titanium dioxide, iron oxide, cobalt oxide, cobalt carbonate, chromium oxide, vanadium pentoxide and cerium oxide.

[0084] In an embodiment of the present disclosure, the pigment is present in an amount in the range of 0.1 mass% to 0.5 mass% with respect to the total mass of the composite material.

[0085] In an embodiment of the present disclosure, the oxidizing agent is at least one selected from the group consisting of benzoyl peroxide (BPO), methyl ethyl ketone peroxide (MEKP) and dicumyl peroxide (DCP).

[0086] In an embodiment of the present disclosure, the oxidizing agent is present in an amount in the range of 0.1 mass% to 0.5 mass% with respect to the total mass of the composite material. In an embodiment of the present disclosure, the curing agent is selected from the group consisting of an azo compound, an acid anhydride and an amine.

[0087] In an embodiment of the present disclosure, the azo compound is selected from the group consisting of azo-bis-isobutyronitrile, azo-bis-isobutyramide and azo-bis-cyanovaleric acid.In an embodiment of the present disclosure, the acid anhydride is selected from the group consisting of maleic anhydride, succinic anhydride, glutaric anhydride, hexahydrophthalic anhydride (HHPA), methyl hexahydrophthalic anhydride (MHHPA), phthalic anhydride, trimellitic anhydride, pyromellitic dianhydride, acetic anhydride and propionic anhydride. In an embodiment of the present disclosure, the amine is selected from the group consisting of ethylenediamine, diethylenetriamine, triethylenetetramine, tetraethylenepentamine, isophorone diamine, 4,4'-diaminodicyclohexylmethane, polyamide amines and polyether amines.

[0088] In an embodiment of the present disclosure, the coupling agent is a silane coupling agent. In an embodiment of the present disclosure, the silane coupling agent is selected from the group consisting of 3-methacryloxypropyltrimethoxysilane, 3 -aminopropyltriethoxy silane and 3 -glycidoxypropyltrimethoxy silane .

[0089] In an embodiment of the present disclosure, the second predetermined speed is in the range of 50 rpm to 100 rpm.

[0090] In still another aspect, the present disclosure provides an article produced by using a composite material. The article is produced by casting the composite material in a mould followed by curing at a temperature in the range of 20 °C to 80 °C to obtain the article.

[0091] In an exemplary embodiment of the present disclosure, the method for the preparation of the article comprises obtaining a composite material, molding and shaping the composite material followed by curing, hardening and demolding to obtain the article. The article is further inspected, and subjected to additional treatment(s) as per specific requirement.

[0092] In an embodiment of the present disclosure, the article is molded into a predefined shape. In an embodiment of the present disclosure, the article is selected from the group consisting of kitchen sink, kitchen workstations, countertops, wash basins, and bathtubs.

[0093] The composite material of the present disclosure and the articles prepared from the composite material exhibits improved thermal resistance, stain resistance, scratch resistance, smooth surface, and is easy to clean. Further, the composite material contains reduced amount of quartz and hence is less harmful.The articles prepared from quartz-rich composite materials which are absent in chamotte or contain low amount of chamotte exhibit poor thermal resistance, i.e., starts cracking / degrading at around 200 °C. Whereas, the articles prepared from the composite material of the present disclosure containing 50 mass% to 80 mass% of chamotte (calcined clay) with respect to the total mass of the composite material exhibit significant improved thermal resistance (above 500 °C), thereby indicating that the incorporation of chamotte substantially enhances resistance to thermal cracking / degradation. The foregoing description of the embodiments has been provided for purposes of illustration and not intended to limit the scope of the present disclosure. Individual components of a particular embodiment are generally not limited to that particular embodiment, but, are interchangeable. Such variations are not to be regarded as a departure from the present disclosure, and all such modifications are considered to be within the scope of the present disclosure.

[0094] The present disclosure is further illustrated herein below with the help of the following nonlimiting examples. The experiments disclosed under these examples herein are intended merely to facilitate an understanding of how the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the experiments should not be construed as limiting the scope of embodiments herein. These laboratory-scale experiments can be scaled up to an industrial / commercial scale and the results obtained can be extrapolated to industrial / commercial scale.

[0095] EXPERIMENTAL DETAILS

[0096] Experiment 1: Preparation of a composite material in accordance with the present disclosure

[0097] The composite material was prepared by following the below mentioned general method.

[0098] A calcined clay and a resin were mixed under stirring at 250 rpm (first predetermined speed) at 27 °C (room temperature) to obtain a resultant mixture. A filler and an additive were added to the resultant mixture, followed by blending at 75 rpm (second predetermined speed) to obtain the composite material.

[0099] Different trials (Trial 1 to Trial 10) were carried out by varying the amount of the ingredients. The ingredients used and their amounts are summarized in Table 1.

[0100]

[0101]

[0102] Experiment 2: Study on the effect of chamotte on thermal resistance

[0103] A study was conducted to evaluate the effect of chamotte content on the thermal resistance of the composite material (Trial 1 to Trial 10) prepared in Experiment 1. The composite material (Trial 1 to Trial 10) obtained in Experiment 1 was casted in a mould (rectangle mould) followed by curing at 60 °C to obtain an article, which was subjected to the thermal resistance study. The articles were gradually heated in a furnace at a rate of 5 °C per minute until visible signs of deformation, cracking, or discoloration appeared. The maximum temperature at which each article retained its structural integrity and dimensional stability was recorded as the thermal resistance of the respective composite and the results obtained are summarized in Table 2.

[0104]

[0105] It is seen from Table 2 that the quartz-rich formulations (Trials 1 to 4) exhibit poor thermal resistance, beginning to degrade at relatively low temperatures (approximately 190 °C to 370 °C). In contrast, chamotte-rich formulations (Trials 5 to 10) show significantly improved thermal stability, with thermal resistance increasing up to 550 °C. Notably, the best thermalresistance is achieved when the composite comprises chamotte (calcined clay) in the range of 50 mass% to 80 mass% and quartz (filler) in the range of 5 mass% to 20 mass%, indicating that a combination of predominantly chamotte with a smaller fraction of quartz provides optimal heat resistance while maintaining the structural integrity of the article. The results confirm that the incorporation of chamotte is critical for producing articles, such as sinks and countertops, capable of withstanding high temperatures without deformation or cracking.

[0106] Experiment 3: Study on the Effect of Chamotte Content on Mechanical Robustness

[0107] Studies were carried out to evaluate the effect of chamotte content on the mechanical strength of composite materials (Trial 1 to Trial 10) prepared in Experiment 1. For the purposes of this study, the mechanical strength is defined as the ability of the article prepared from the composite materials to withstand static compressive loading, accidental dropping, and sudden impact without structural failure. Each of the composite material (Trial 1 to Trial 10) was cast into rectangular moulds and cured at 60 °C to obtain an article. After curing, the articles were cooled to 27 °C (room temperature) and visually inspected to confirm the absence of visible cracks or defects.

[0108] Mechanical strength was evaluated using a combination of compressive strength testing, drop strength testing, and impact strength testing, as described below and the results obtained are summarized in Table 3.

[0109] Compressive Strength Test

[0110] Compressive strength was measured using a universal testing machine in accordance with ASTM C39 / C39M and ISO 604 test principles. Each sample was subjected to an increasing compressive load applied at a constant rate until failure or visible cracking occurred. The maximum load sustained prior to failure was recorded and used to calculate the compressive strength of the composite material.

[0111] Drop Strength Test

[0112] Drop strength was evaluated by releasing each article from progressively increasing heights onto a rigid steel surface, following general procedures consistent with ASTM D5276 and ISO 2248. The drop height was increased in fixed increments until cracking, chipping, orcatastrophic fracture of the article was observed. The maximum drop height at which the article remained structurally intact was recorded as the drop strength.

[0113] Impact Strength Test

[0114] Impact strength was measured using a pendulum-type impact tester in accordance with ASTM D256 (Izod) and ISO 179 (Charpy) test methodologies. Each specimen was subjected to a single impact event, and the energy absorbed prior to fracture was recorded as an indicator of the impact strength and toughness of the composite material.

[0115]

[0116] It is seen from Table 3 that the articles prepared from composite material containing relatively high proportions of quartz and lower amount of chamotte (Trials 1 to 3) exhibit inferior mechanical strength, characterized by lower compressive strength, reduced resistance to drop-induced damage, and lower impact energy absorption. These articles were prone to brittle failure under both static and dynamic loading conditions. A progressive improvement in mechanical strength is observed as the chamotte content increases from Trial 4 through Trial 9. This improvement observed is due to the refractory, calcined structure of chamotte, which promotes enhanced load distribution, crack deflection, and energy absorption within the composite material. The presence of a limited amount of quartz filler further contributes to dimensional stability and optimized particle packing. The highest overall mechanical strength is achieved in formulations comprising chamotte in the range of 50 mass% to 80 mass% and quartz in the range of approximately 5 mass% to 20 mass%. Further, when quartz is absent in the composite material a comparatively lower mechanical strength is observed. The results demonstrate that the composite materials comprising chamotte (50 mass% to 80mass%) along with filler (5 mass% to 20 mass%) exhibit significantly improved mechanical strength.

[0117] The results demonstrate that the incorporation of chamotte (50 mass% to 80 mass%) is critical for producing articles exhibiting superior resistance to compressive loads, accidental dropping, and impact forces.

[0118] Experiment 4: Study on the Effect of Chamotte Content on stain resistance

[0119] Studies were carried out to evaluate the effect of chamotte content on the stain resistance of composite materials (Trial 1 to Trial 10) prepared in Experiment 1. Each of the composite material (Trial 1 to Trial 10) was cast into rectangular moulds and cured at 60 °C to obtain an article. All articles were surface-finished in a comparable manner to minimize variations in surface roughness and appearance.

[0120] Prior to testing, the articles were cleaned and dried to remove surface contaminants. Stain resistance was evaluated by exposing the surface of each article to commonly encountered staining agents (turmeric stain, coffee stain, red wine stain, and beetroot stain) representative of kitchen and household environment. The testing methodology followed procedures generally consistent with ISO 10545-14 and ASTM C1378, with adaptations appropriate for composite materials. The staining agents were allowed to remain in contact with the surface of the article for 30 minutes, after which the surfaces were cleaned with water and a mild detergent. The articles were then visually inspected under consistent lighting conditions and evaluated for residual staining.

[0121] Stain resistance was rated on a qualitative numerical scale, where:

[0122] • 5 = No visible stain after cleaning

[0123] • 4 = Slight discoloration, barely perceptible

[0124] • 3 = Moderate visible stain

[0125] • 2 = Strong visible stain

[0126] • 1 = Severe staining not removable by cleaning

[0127] The results obtained are summarized in Table 4.

[0128]

[0129]

[0130] It is seen from Table 4, that the articles prepared from composite materials containing relatively high proportions of quartz and lower amount of chamotte (Trials 1 to 4) exhibit inferior stain resistance, with visible discoloration remaining after cleaning, due to increased surface porosity and enhanced affinity for staining agents. As the chamotte content increases from Trial 5 through Trial 9, a marked improvement in stain resistance is observed. The calcined nature of chamotte contributes to reduced surface reactivity and improved microstructural stability, thereby limiting the penetration and retention of staining agents. The highest stain resistance ratings are observed in composite materials comprising chamotte in the range of 50 mass% to 80 mass% and quartz in the range of 5 mass% to 20 mass%. Further, when quartz is absent in the composite material a lower stain resistance is observed. The results demonstrate that the composite materials comprising chamotte (50 mass% to 80 mass%) along with filler (5 mass% to 20 mass%) exhibit significantly improved stain resistance.

[0131] The articles prepared from the composite material of the present disclosure provide improved mechanical strength, thermal resistance and stain resistance. The composite material of the present disclosure is suitable for manufacturing articles such as sinks, countertops, and similar structural components, that are subjected to mechanical shock and elevated temperatures during normal use.

[0132] TECHNICAL ADVANCEMENTS

[0133] The present disclosure described hereinabove has several technical advantages including, but not limited to, the realization of

[0134] a composite material that;

[0135] • is environment friendly, andan article prepared from a composite material that

[0136] • has improved stain resistance;

[0137] • has smooth surface;

[0138] • is durable and easy to clean; and

[0139] • are aesthetic and durable.

[0140] Throughout this specification the word “comprise”, or variations such as “comprises” or “comprising, will be understood to imply the inclusion of a stated element, integer or step,” or group of elements, integers or steps, but not the exclusion of any other element, integer or step, or group of elements, integers or steps.

[0141] The use of the expression “at least” or “at least one” suggests the use of one or more elements or ingredients or quantities, as the use may be in the embodiment of the invention to achieve one or more of the desired objects or results. While certain embodiments of the inventions have been described, these embodiments have been presented by way of example only, and are not intended to limit the scope of the inventions. Variations or modifications to the formulation of this invention, within the scope of the invention, may occur to those skilled in the art upon reviewing the disclosure herein. Such variations or modifications are well within the spirit of this invention.

[0142] The numerical values given for various physical parameters, dimensions and quantities are only approximate values and it is envisaged that the values higher than the numerical value assigned to the physical parameters, dimensions and quantities fall within the scope of the invention unless there is a statement in the specification to the contrary.

[0143] While considerable emphasis has been placed herein on the specific features of the preferred embodiment, it will be appreciated that many additional features can be added and that many changes can be made in the preferred embodiment without departing from the principles of the disclosure. These and other changes in the preferred embodiment of the disclosure will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the disclosure and not as a limitation.

Claims

CLAIMS:

1. A composite material comprising:• a resin in an amount in the range of 15 mass% to 30 mass% with respect to the total mass of said composite material;• a calcined clay in an amount in the range of 50 mass% to 80 mass% with respect to the total mass of said composite material;• a filler in an amount in the range of 5 mass% to 20 mass% with respect to the total mass of said composite material; and• an additive in an amount in the range of 0.1 mass% to 1 mass% with respect to the total mass of said composite material.

2. The composite material as claimed in claim 1, wherein said resin is an acrylic resin.

3. The composite material as claimed in claim 1, wherein said calcined clay is at least one selected from the group consisting of metakaolin, montmorillonite, bentonite, kaolinite, palygorskite and chamotte.

4. The composite material as claimed in claim 1, wherein said filler is at least one selected from the group consisting of quartz, olivine, feldspar, pyroxene, mica, granite and ceramic.

5. The composite material as claimed in claim 1, wherein said additive is at least one selected from the group consisting of a pigment, an oxidizing agent, a curing agent and a coupling agent.

6. The composite as claimed in claim 5, wherein• said pigment is selected from the group consisting of tin oxide, titanium dioxide, iron oxide, cobalt oxide, cobalt carbonate, chromium oxide, vanadium pentoxide and cerium oxide;• said oxidizing agent is selected from the group consisting of benzoyl peroxide (BPO), methyl ethyl ketone peroxide (MEKP) and dicumyl peroxide (DCP);• said curing agent is selected from the group consisting of an azo compound, an acid anhydride and an amine; and• said coupling agent is a silane coupling agent.

7. A method for the preparation of a composite material, said method comprising the following steps:a. mixing predetermined amounts of a calcined clay and a resin under stirring at a first predetermined speed to obtain a resultant mixture; andb. adding predetermined amounts of a filler and an additive to said resultant mixture, followed by blending at a second predetermined speed to obtain said composite material.

8. The process as claimed in claim 7, wherein said first predetermined speed is in the range of 200 rpm to 300 rpm.

9. The process as claimed in claim 7, wherein said second predetermined speed is in the range of 50 rpm to 100 rpm.

10. An article produced by using a composite material as claimed in claim 1, by casting said composite material in a mould followed by curing at a temperature in the range of 20 °C to 80 °C to obtain said article.

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