Artificial Marble Production Using TPU Resin and Granite Soil
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Solution Overview
Problem
Conventional methods for manufacturing artificial marble are limited by the use of harmful components, high environmental impact, and inability to create permeable and durable flooring materials with thermosetting polyurethane resins, which lack elasticity and permeability.
Innovation Solution
An apparatus that independently heats granite soil and mixes it with a thermoplastic polyurethane (TPU) resin to produce a sheet-shaped artificial marble, eliminating the need for reaction initiators and solvents, and utilizing the TPU resin's elasticity and solid-phase properties to enhance durability and permeability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If thermosetting polyurethane resin is used to manufacture artificial marble, then the material achieves sufficient strength and durability, but it lacks elasticity and permeability, and requires harmful reaction initiators and solvents
Solution Approach 1:
The patent changes the fundamental parameter of resin type from thermosetting polyurethane to thermoplastic polyurethane. This parameter change eliminates the need for harmful reaction initiators and solvents while simultaneously providing elasticity and permeability. The thermoplastic resin achieves durability through its molecular structure and processing methods rather than chemical cross-linking
Solution Approach 2:
The patent utilizes phase transitions of thermoplastic polyurethane resin between solid and molten states during processing. The resin is heated to a molten state for mixing and molding, then cooled to solidify into the final artificial marble product. This phase transition approach eliminates the need for chemical hardening agents and provides inherent elasticity to the finished product
2Shape
If natural stone is used for building walls, then excellent design value and texture are achieved, but quarrying depletes natural resources and destroys ecosystems
Solution Approach 1:
The patent creates artificial marble that copies the appearance, texture, and design characteristics of natural granite and marble. By using granite soil as a raw material and combining it with thermoplastic polyurethane resin, the invention reproduces the aesthetic qualities of natural stone without requiring quarrying, thus eliminating environmental destruction while maintaining design value
Solution Approach 2:
The patent develops a composite material consisting of granite soil particles embedded in a thermoplastic polyurethane resin matrix. This composite reproduces the visual characteristics of natural granite while incorporating synthetic materials that eliminate the need for resource-intensive quarrying operations
3Ease of manufacture
If artificial marble is manufactured by mixing acrylic polymer resin with mineral fillers and curing it, then a sheet-shaped semi-finished product is produced, but the material is imperforate and lacks elasticity
Solution Approach 1:
The patent changes the resin parameter from acrylic polymer to thermoplastic polyurethane, which inherently provides elasticity and can form permeable structures. The thermoplastic resin's viscoelastic properties allow the manufactured artificial marble to exhibit elastic behavior and potential permeability, unlike rigid acrylic-based materials
4Strength
If natural stone is made relatively thick for safety, then building safety is ensured, but cost increases and processing becomes difficult
Solution Approach 1:
The patent uses a composite material structure where thermoplastic polyurethane resin binds granite soil particles together, creating a unified artificial marble product with consistent mechanical properties throughout. This composite approach eliminates the need for thick sections to ensure safety, as the bonded structure provides uniform strength and stability at reduced thickness
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 continuous production of safe, elastic, and permeable artificial marble with reduced environmental impact, suitable for various building materials and flooring, while maintaining the natural appearance and texture of granite, and allowing for recyclability.
Implementation Method 1
a granite soil heating unit configured to heat the granite soil supplied from the granite soil storage unit
Implementation Method 2
a mixing-transporting unit configured to accommodate the TPU resin and the heated granite soil therein and then melting and mixing them to produce and simultaneously transport an artificial marble slurry
Data Source
AI summary
The present invention provides an apparatus for manufacturing artificial marble, which includes a granite soil storage unit configured to supply a granite soil by storing, drying, and heating it, a granite soil heating unit configured to heat the granite soil supplied from the granite soil storage unit, a resin storage unit configured to store a thermoplastic polyurethane (TPU) resin maintained in a solid phase at room temperature, a mixing-transporting unit configured to accommodate the TPU resin and the heated granite soil therein and then melting and mixing them to produce and simultaneously transport an artificial marble slurry, a material guide unit configured to guide the granite soil and the TPU resin into the mixing-transporting unit, a discharge unit configured to discharge the artificial marble slurry mixed in the mixing-transporting unit by a certain amount, a mold supply unit configured to continuously supply a mold for accommodating and molding the artificial marble slurry therein, a mold guide unit configured to guide the mold supplied from the mold supply unit downward of the discharge unit to accommodate the artificial marble slurry in the mold, a forming unit configured to form an artificial marble by applying vibration and pressure to the artificial marble slurry accommodated in the mold, an extraction unit configured to extract the mold accommodating the artificial marble, and a lamination unit configured to laminate and store the mold extracted by the extraction unit.