Transparent Amorphous Pattern Artificial Marble Shrinkage Control
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Solution Overview
Problem
Existing artificial marble technologies struggle to create transparent amorphous patterns with three-dimensional representation while preventing the concave phenomenon and ensuring surface smoothness, as transparent resins used for patterns shrink more than the matrix resin, leading to cracking and pattern migration due to differences in specific gravity.
Innovation Solution
A method involving a pattern part forming resin composition with a halogenated urethane acrylate or epoxy acrylate binder and acrylic polymerizable monomer, combined with an inorganic filler like aluminum hydroxide, to achieve a specific gravity of 1.6 to 2.0 for the pattern part, minimizing shrinkage and migration, and using a matrix forming slurry with dissolved polyacrylate and acrylic monomer to create an artificial marble with a transparent amorphous pattern.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If transparent resin is used to form pattern parts in artificial marble, then transparency of the pattern parts is improved, but shrinkage during hardening increases causing cracking at the interface between pattern part and matrix
Solution Approach 1:
The patent changes the chemical composition parameters of the pattern part forming resin by using a specific mixture of binder (halogenated urethane acrylate or epoxy acrylate) and acrylic polymerizable monomer in controlled ratios. This parameter optimization reduces shrinkage during curing while maintaining transparency, preventing cracking at the pattern-matrix interface.
Solution Approach 2:
The patent creates a composite resin system combining halogenated urethane acrylate or epoxy acrylate binder with acrylic polymerizable monomer. This composite material leverages the low shrinkage characteristics of acrylic polymers while maintaining the transparency and aesthetic properties needed for pattern parts.
2Stability of the object's composition
If inorganic filler is introduced to increase specific gravity at the matrix level, then specific gravity control is improved, but transparency of the pattern part significantly decreases
Solution Approach 1:
The patent applies local quality by introducing inorganic filler (aluminum hydroxide) selectively into the matrix resin composition rather than uniformly throughout the entire artificial marble. This localized addition allows specific gravity control at the matrix level without compromising the transparency of the pattern parts, as the filler is excluded from or minimally present in the transparent pattern regions.
3Illumination intensity
If transparent resin is used for pattern parts, then transparency is improved, but pattern migration to upper portion occurs due to excessive difference in specific gravity between matrix resin and pattern part
Solution Approach 1:
The patent optimizes the specific gravity parameter of the pattern part by adjusting the binder-to-monomer ratio in the resin composition. By controlling this parameter to achieve a specific gravity difference within an acceptable range (1.05 to 1.20) relative to the matrix resin, the patent prevents excessive migration of pattern parts to the upper portion while maintaining transparency.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enables the production of artificial marble with a natural three-dimensional pattern and high transparency, preventing the concave phenomenon and ensuring good surface smoothness by balancing the shrinkage ratio between the pattern and matrix parts.
Implementation Method 1
The pattern part is formed by hardening (also referred to herein as curing) a pattern part forming resin composition (A) comprising a binder and an acrylic polymerizable monomer
Implementation Method 2
The pattern part forming resin composition (A) can further include an inorganic filler in an amount of about 0.1 to about 50 parts by weight based on about 100 parts by weight of a mixture of the binder and the acrylic polymerizable monomer. The inorganic filler may be aluminum hydroxide.
Implementation Method 3
mixing a dissolved polyacrylate and an acrylic monomer to prepare a matrix forming slurry (B) for forming the matrix of the artificial marble
Data Source
AI summary
Artificial marble having a transparent amorphous pattern includes a base or matrix material portion and a transparent pattern portion. The pattern portion has a specific gravity or about 1.60 or more and is formed by hardening or curing a resin composition comprising a binder selected from halogenated urethane acrylates, halogenated epoxy acrylates and combinations thereof and an acrylic polymerizable monomer.