Moldable Engineered Stone via Ionic Crosslinking
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing engineered stone compositions face challenges in production due to limited means of producing composite shapes and require casting methods that involve vibration and vacuum, leading to batch variations and extensive setup and cleanup operations.
Innovation Solution
The development of engineered stone compositions that can be extruded and molded, utilizing a matrix resin with carboxylic acid groups that form ionic links with metal oxides or hydroxides to increase viscosity, allowing for the creation of a solid, flexible sheet that can be cured in a mold through covalent crosslinking, thereby avoiding casting issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If casting methods are used to produce engineered stone compositions, then a stone-like surface can be obtained, but the production process requires vibration and vacuum, leading to batch variations and extensive setup and cleanup operations
Solution Approach 1:
The invention changes the chemical parameters of the resin matrix by incorporating carboxylic acid groups that form ionic links with metal oxides and hydroxides. This chemical modification allows the composite to be molded without vibration and vacuum, eliminating the complex casting equipment while maintaining stone-like surface quality through the ionic crosslinking mechanism
Solution Approach 2:
The invention replaces the mechanical casting system (requiring vibration and vacuum equipment) with a chemical system based on ionic crosslinking. The carboxylic acid groups in the resin matrix chemically interact with metal oxides and hydroxides to form ionic links, enabling the composite to set and bond without mechanical vibration or vacuum assistance, thus eliminating complex production equipment
2Ease of manufacture
If casting methods are used to produce engineered stone compositions, then the composite can be formed, but batch variations occur and extensive setup and cleanup operations are required
Solution Approach 1:
The invention modifies the chemical composition parameters by adding carboxylic acid groups to the resin matrix, which create ionic links with metal oxides and hydroxides. This chemical change enables consistent bonding behavior across batches, improving reliability while simplifying the manufacturing process by eliminating vibration and vacuum requirements
Solution Approach 2:
The carboxylic acid groups act as intermediaries between the resin matrix and metal oxides/hydroxides, forming ionic links that provide consistent bonding. This intermediary mechanism ensures reliable and repeatable results across production batches, eliminating batch variations while maintaining ease of manufacture
3Manufacturing precision
If a higher percentage of mineral particulate (80-95% by weight) is used in engineered stone compositions, then a stone-like surface is provided, but the limited means of producing the composite and shape constraints result
Solution Approach 1:
The invention changes the chemical parameters of the resin matrix by incorporating carboxylic acid groups that form ionic links with metal oxides and hydroxides. This chemical modification enables high mineral particulate content (80-95% by weight) to be used while simultaneously providing shape flexibility, as the ionic crosslinking allows the composite to be molded into various shapes without requiring casting methods
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
This method enables the production of engineered stone products with a smooth stone-like surface, offering improved fabricability and consistency in shape, reducing batch variations and production complexities, while allowing for continuous extrusion and molding processes.
Implementation Method 1
carboxylic acid groups of the polymer in a matrix resin interact with certain metal oxides and hydroxides to form ionic links that greatly increase the viscosity of the matrix resin to the point of solidifying the composite
Implementation Method 2
crosslinked with additional monomer through a free radical initiator forming covalent bonds
Data Source
AI summary
This invention provides a moldable engineered stone composition comprising an ethylenically unsaturated acrylic polymer capable of being covalently crosslinked, a mineral particulate, and an ionic crosslinking agent which forms ionic bonds within the syrup of unsaturated acrylic polymer via unreacted acid groups, causing thickening prior to curing and prior to the formation of covalent bonds via the double bonds of the polymer chain. The composition is then capable of being extruded and molded in a press. Articles formed by curing the composition and methods for producing the composition are also disclosed.