Stone Agglomerate Panels Using Plant-Origin Polyol Binders
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Solution Overview
Problem
Current manufacturing processes for stone agglomerates rely heavily on petrochemical-based resins, which require substantial infrastructure changes and are not environmentally friendly, despite efforts to use recycled and renewable materials.
Innovation Solution
Partial substitution of petrochemical polyols in polyester resins with polyols from plant origins, such as corn, in the production of stone agglomerates, allowing for the use of recycled materials and maintaining existing process infrastructure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If petrochemical-based resins are used for manufacturing stone agglomerates, then the material achieves good mechanical properties and durability, but the environmental impact increases and reliance on non-renewable resources worsens
Solution Approach 1:
The patent changes the chemical composition parameters of the resin by substituting petrochemical polyols with plant-origin polyols (such as corn polyol). This parameter change maintains the resin's binding functionality while improving environmental sustainability and reducing dependence on non-renewable resources.
Solution Approach 2:
The patent creates a composite resin system combining plant-origin polyols with traditional polyester resin components. This composite approach allows the material to retain the mechanical properties of conventional resins while incorporating renewable ingredients, thus balancing performance and environmental considerations.
2Object-affected harmful factors
If plant-origin polyols are used to substitute petrochemical polyols, then environmental friendliness improves, but the infrastructure requirements and process compatibility may be affected
Solution Approach 1:
The patent carefully controls the substitution level of plant-origin polyols (typically 10-50% by weight) to maintain compatibility with existing manufacturing processes. This parameter optimization ensures that the resin mixture cures properly and works with standard equipment while still achieving environmental benefits.
3Quantity of substance
If high content of recycled materials is used in stone agglomerates, then the use of renewable resources improves, but the mechanical strength and structural integrity may be compromised
Solution Approach 1:
The patent uses the plant-origin resin as a binding matrix that holds recycled stone particles together. The resin's adhesive properties compensate for the structural weaknesses of recycled materials, creating a composite where the weak recycled particles are embedded in a strong continuous matrix, achieving both sustainability and strength.
Solution Approach 2:
The patent optimizes the distribution and orientation of recycled materials within the resin matrix. By controlling the local arrangement of recycled particles and ensuring proper resin infiltration, the material achieves uniform strength properties throughout while maximizing recycled content.
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 use of plant-origin polyols in polyester resins results in environmentally friendly stone agglomerates with improved mechanical and aesthetic properties, suitable for indoor use, while reducing the reliance on petrochemical products and enabling high recycling content without requiring significant process modifications.
Implementation Method 1
an organic binder and additives is formed, in amounts suitable to make the formation of said material possible by means of the simultaneous action of vacuum compression and vibration
Data Source
AI summary
The present invention relates to panels or slabs formed by stone agglomerate for the manufacture of which an organic binder containing an ingredient of a plant origin is used. The panels or slabs object of the invention are formed from stone materials or the like, granulated and subsequently agglomerated by means of a binder, specifically an organic resin containing one or more polyols of a plant origin.Furthermore, by means of using this binder together with materials from waste and used and/or recycled products, a material with good features and with a very high content of recycled material or material of a renewable origin can be obtained.The manufactured panel or slab containing a resin part of a plant origin of the present invention is particularly suitable for its use indoors as a kitchen counter, a bathroom counter, or any work surface, as well as for its use as flooring or sidings.