Artificial Silica Marble Amorphous Pattern via Segmented Resin Injection
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Solution Overview
Problem
Conventional methods for producing artificial marble do not replicate the lump-shaped amorphous pattern of natural marble, despite advancements in materials and processes.
Innovation Solution
An artificial silica marble is created with a matrix and a line pattern portion comprising fine lines that divide the marble into irregularly shaped portions, using a method involving dry-mixing silica powder and sand with pigments, followed by wet-mixing with unsaturated polyester resin, crushing, and dispersing a second pigment-containing mixture to form amorphous patterns through molding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional mixing methods are used to prepare artificial marble, then the production process is simple, but the amorphous pattern of natural marble cannot be replicated
Solution Approach 1:
The patent divides the artificial marble into distinct components: a matrix phase and separate line pattern portions. The line pattern portion is created by injecting a different resin composition through nozzles to form web- or net-like patterns that partition the marble into lump-shaped regions, replicating natural marble's amorphous appearance without requiring complex overall process redesign
Solution Approach 2:
The patent prepares the line pattern portion resin composition in advance with specific viscosity characteristics (higher than the matrix resin) and incorporates coloring agents before the injection step. This preliminary preparation ensures that when the resin is injected into the molding cell, it naturally forms the desired web-like patterns that create the amorphous appearance
2Stability of the object's composition
If resin viscosity is controlled to prevent sedimentation, then material stability is improved, but the ability to form lump-shaped amorphous patterns is limited
Solution Approach 1:
The patent applies different viscosity characteristics to different parts of the resin system. The matrix resin maintains lower viscosity for stability and ease of mixing, while the line pattern portion resin has higher viscosity to prevent sedimentation of inorganic fillers and to enable proper pattern formation during injection. This local differentiation resolves the contradiction between stability and pattern formation capability
3Strength
If inorganic fillers are added to resin, then surface quality and mechanical strength are improved, but sedimentation occurs during processing
Solution Approach 1:
The patent changes the viscosity parameter of the line pattern portion resin to be higher than the matrix resin. This viscosity increase prevents sedimentation of inorganic fillers (such as ferrosilicon or silicon metal) during processing while still allowing the fillers to provide their intended mechanical strength and surface quality benefits. The higher viscosity creates a more stable suspension environment for the heavy inorganic particles
Data Source
AI summary
An artificial silica marble comprises a matrix and a line pattern portion. The line pattern portion comprises fine lines having a width of about 50 to about 500 μm and forms a web- or net-like pattern. The line pattern portion divides or partitions the artificial silica marble into a plurality of irregularly shaped pattern portions to form an amorphous pattern in the cross section of the artificial silica marble.