Engineered Stone Composite Vibration Compaction
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Solution Overview
Problem
Existing synthetic stone compositions have surfaces that predominantly reflect resin properties rather than aggregate properties, lacking the necessary strength, abrasion resistance, hardness, and chemical resistance for applications like flooring and outdoor use, and natural stone is brittle and difficult to cut into thin slices.
Innovation Solution
A three-step molding process combining siliceous or calcareous mineral particulate with a crosslinkable resin and binding agent, involving vibration, vacuum, and high-pressure compaction, followed by polymerization and repeated molding to create a dense, strong engineered stone composite suitable for veneers and other applications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If high percentages of resin are used in synthetic stone compositions, then fabricability and molding properties are improved, but abrasion resistance, hardness, and chemical resistance deteriorate
Solution Approach 1:
The patent changes the chemical composition parameters by using 70-90 wt% aggregate and only 10-30 wt% resin, which is the opposite of conventional synthetic stone. This parameter change allows the composition to achieve both good fabricability and improved abrasion resistance, hardness, and chemical resistance by optimizing the resin-to-aggregate ratio.
Solution Approach 2:
The patent creates a composite material consisting of aggregate particles embedded in a resin matrix, where the aggregate provides abrasion resistance, hardness, and chemical resistance while the resin provides binding and fabricability. The specific composition range of 70-90 wt% aggregate and 10-30 wt% resin optimizes the properties of both components.
2Stability of the object's composition
If natural stone is used for veneer applications, then aesthetic properties are improved, but ease of cutting and processing deteriorates
Solution Approach 1:
The patent creates an artificial copy of natural stone by using aggregate particles that resemble natural stone in appearance, combined with a resin matrix that can be easily molded and cut. The aggregate provides the natural stone aesthetic while the resin-based composite allows for easy fabrication, cutting, and processing into various shapes and sizes.
3Device complexity
If conventional molding processes are used for synthetic stone, then manufacturing simplicity is improved, but bond strength between aggregate and resin deteriorates
Solution Approach 1:
The patent incorporates a binding agent in the resin composition before molding, which preliminarily prepares the resin-aggregate interface for strong bonding. The binding agent, present at 5-20 wt% of the resin weight, pre-establishes adhesive properties that ensure strong bond strength during the molding process, eliminating the need for complex post-processing or specialized molding techniques.
4Adaptability or versatility
If thin slabs are manufactured from natural stone, then versatility for veneer applications is improved, but structural integrity deteriorates
Solution Approach 1:
The patent creates a composite material where the resin matrix provides structural integrity and binding strength while the aggregate particles provide aesthetic properties. This composite structure allows the manufacturing of thin slabs with high structural integrity that would be difficult to achieve with natural stone, enabling versatile veneer applications while maintaining strength and durability.
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 process results in engineered stone composites with enhanced strength, abrasion resistance, and chemical resistance, allowing for the creation of thin slabs that can be laminated to rigid substrates and exhibit a polished surface similar to natural stone, suitable for various architectural and decorative uses.
Implementation Method 1
The compacted composite is then heated to cause the polymerization and crosslinking of the resin to obtain the engineered stone
Implementation Method 2
The mixture is compacted by vibration and then molded into preferably a slab under high pressures while applying a vacuum to the mold to reduce the size of the aggregate in the mold by about half
Implementation Method 3
molded into preferably a slab under high pressures while applying a vacuum to the mold to reduce the size of the aggregate in the mold by about half
Implementation Method 4
The compacted composite is then heated to cause the polymerization and crosslinking of the resin to obtain the engineered stone
Data Source
AI summary
The present invention relates to an engineered stone composite produced from a mineral aggregate, a synthetic resin and a binder using compression and vibration to obtain a high strength mineral composite with a high mineral content and a method for its preparation.