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WO2010093714A1 - Composition de quartz synthétique améliorée et son procédé de fabrication - Google Patents

Composition de quartz synthétique améliorée et son procédé de fabrication Download PDF

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Publication number
WO2010093714A1
WO2010093714A1 PCT/US2010/023781 US2010023781W WO2010093714A1 WO 2010093714 A1 WO2010093714 A1 WO 2010093714A1 US 2010023781 W US2010023781 W US 2010023781W WO 2010093714 A1 WO2010093714 A1 WO 2010093714A1
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WO
WIPO (PCT)
Prior art keywords
approximately
synthetic quartz
quartz
composition
resin
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/US2010/023781
Other languages
English (en)
Inventor
Wesley Moore
Phil Chang
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Individual
Original Assignee
Individual
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from US12/368,562 external-priority patent/US20100048772A1/en
Application filed by Individual filed Critical Individual
Priority to US13/148,940 priority Critical patent/US20120283087A1/en
Publication of WO2010093714A1 publication Critical patent/WO2010093714A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

Links

Classifications

    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B26/00—Compositions of mortars, concrete or artificial stone, containing only organic binders, e.g. polymer or resin concrete
    • C04B26/02—Macromolecular compounds
    • C04B26/04—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • C04B26/06—Acrylates
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B26/00—Compositions of mortars, concrete or artificial stone, containing only organic binders, e.g. polymer or resin concrete
    • C04B26/02—Macromolecular compounds
    • C04B26/10—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
    • C04B26/12—Condensation polymers of aldehydes or ketones
    • C04B26/122—Phenol-formaldehyde condensation polymers
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B26/00—Compositions of mortars, concrete or artificial stone, containing only organic binders, e.g. polymer or resin concrete
    • C04B26/02—Macromolecular compounds
    • C04B26/10—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
    • C04B26/14—Polyepoxides
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B26/00—Compositions of mortars, concrete or artificial stone, containing only organic binders, e.g. polymer or resin concrete
    • C04B26/02—Macromolecular compounds
    • C04B26/10—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
    • C04B26/16—Polyurethanes
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B26/00—Compositions of mortars, concrete or artificial stone, containing only organic binders, e.g. polymer or resin concrete
    • C04B26/02—Macromolecular compounds
    • C04B26/10—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
    • C04B26/18—Polyesters; Polycarbonates
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L63/00—Compositions of epoxy resins; Compositions of derivatives of epoxy resins
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/54—Substitutes for natural stone, artistic materials or the like
    • C04B2111/542—Artificial natural stone
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K5/00—Use of organic ingredients
    • C08K5/16—Nitrogen-containing compounds
    • C08K5/17—Amines; Quaternary ammonium compounds
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K5/00—Use of organic ingredients
    • C08K5/54—Silicon-containing compounds
    • C08K5/541—Silicon-containing compounds containing oxygen
    • C08K5/5425—Silicon-containing compounds containing oxygen containing at least one C=C bond

Definitions

  • This new invention is directed to an improved synthetic quartz product and a production process therefor.
  • Synthetic quartz sometimes called artificial marble, has very favorable chemical and physical properties including resistance to acids, corrosion, high temperatures, wear, impact, compression, bending and infiltration. It is also very easy to install and keep clean. Synthetic quartz can be manufactured in many patterns including simulated marble or granite, can be given features like a natural marble-like smoothness, granitic strength, and ceramic luster, and can be formed into many shapes. Handsome and practical synthetic quartz is an ideal modern architectural decorative material.
  • the major raw materials generally used in the production of synthetic quartz under current production techniques are quartz, quartz powder and resin. Resin is used to combine all the materials into a very strong and solid finished product.
  • Resins commonly used are unsaturated polyester resin, epoxy, phenolic resin, acrylic resin and polyurethane resin.
  • the invention is directed to providing an improved synthetic quartz product having superior physical properties achieved by adding fiber particles to the raw materials conventionally use to produce synthetic quartz.
  • the improved synthetic quartz has tensile strength, compression strength and bending strength ratings that meet or exceed ASTM standards for natural quartz.
  • improved synthetic quartz comprises a combination of the following elements in the percentages indicated according to weight: quartz stones 0-90%, quartz powder 5-90%, resin 0.1-20%, fiber 1-25%, coupling agent 0.1-5%, curing agent 0.1-5%, glass chip 0-70%, mirror chip 0-70%, pigment 0-5%, shell chip 0-5%. and metal flake 0-5%.
  • One embodiment of the invention having good physical properties has the following formulation (unless otherwise specified, all percentages indicated the percent by weight of the indicated to total weight of the combination): quartz stone 30-35%, quartz powder 45-50%, resin 6-8%, fiber 3-5%, coupling agent 0.1-1 %, curing agent 0.1-0.5%, glass chip 15-20%, and pigment 0.1-1 %.
  • Another embodiment of the invention having better physical properties has the following formulation: quartz stone 5-6%, quartz powder 32-33%, glass chip 51-55%, fiber 5-7%, resin 6.5-7%, coupling agent 0.1-0.2%, curing agent 0.1-0.2%, and pigment 0.1-0.5%.
  • a third embodiment of the invention having excellent physical properties has the following formulation: quartz stone 47%, quartz powder 41.65%, resin 8%, fiber 3%, coupling agent 0.1 %, curing agent 0.05%, and pigment 0.2%.
  • a fourth embodiment of the invention also having excellent physical properties has the following formulation: quartz powder 32.65%, glass chip 55%, resin 7%, fiber 5%, coupling agent 0.1 %, curing agent 0.05%, and pigment 0.2%.
  • the particle size of the quartz powder according to the invention is from 0.1 to 20 mm, but the most frequently used size is between 0 and 2 mm. The best size are 0-1 mm, 0-2 mm, 1-2 mm, 3-5 mm, 5-8 mm and 8-12 mm, and pureness above 80.
  • the purpose of quartz powder is to act as a filler. If the particle size is too big, the quartz powder will not function as a filler; conversely, if the particle size is too small, the quartz powder will absorb too much resin resulting in an undesirable increase in cost. Tests have determined that a particle size between 300 and 2000 mesh strikes a good balance between performing well as filler and keeping costs to a practicable minimum.
  • the size of the glass chip, shell chip and metal flake are each 0.1-25 mm.
  • suitable fibers are one or a combination of fiberglass, carbon fiber, basalt fiber and boron fiber; however, it will be appreciated by those of skill in the art that other fiber building materials may be substituted it correspondingly favorable properties result.
  • Resin acts as a binding agent. When the curing agent is introduced to a mixture of resin in its liquid phase, quartz powder and other ingredients, the resin hardens into a solid such that the resulting mixture cures into a high density, high strength solid quartz product.
  • Suitable resins are one or a combination of unsaturated polyester resin, epoxy, phenolic resin, acrylic resin and polyurethane resin, but it will be understood that other binding resins having similar binding properties may be used.
  • the invention described curing agents are the field of conventional curing agents. Curing agents reinforce and induce the resin to cure into a solid condition. Suitable curing agents according to the invention are one or a multiple of methyl ethyl ketone peroxide (MEKP) and/or fat multi-amines.
  • MEKP methyl ethyl ketone peroxide
  • Suitable fat multi-amines include ethylenediamine, diethylenetriamine, triethylenebutamine, butaethylenepentamine, polyethylenepolyamine, dipropenetriamine, dimethylaminepropylamine, diethylaminepropylamine, 3-methyl-6-diamine, dihexyltriamine, tert-butyl peroxy-2-ethylhexanoate (TBPO), hexamethylenediamine.
  • TPO tert-butyl peroxy-2-ethylhexanoate
  • the coupling agent increases the particle surface roughness and provides the bonding force between two quartz particles. It has been determined that a RSiX 3 R which stands for amino(-NH 2 ), sulfhydryl (HS-), vinyl (CH 2 :CH), epoxy, cyano(N ⁇ C-), methacryloxyl (CH 2 :C(CH 3 )CO) groups. These groups have stronger reactivity with resins.
  • X stands for the hydrolysis alkoxy (e.g., methoxy and ethoxy).
  • a suitable silane coupling agent is ⁇ -methacryloxylpropyl-trimethylsilicane, ⁇ -(2,3-epoxypropane) propyl-trimethylsilicane, N- ⁇ (aminoethyl)- ⁇ -aminoproplymethyldimethoxysilicane, N-( ⁇ -aminoethyl)- ⁇ -aminoproplytrim-ethylsilicane.
  • Pigments suitable for use in the combination according to the invention are ferric pigment (e.g., iron black, iron yellow and iron red), phthalocyanine pigments (e.g., phthalocyanine green blue and phthalocyanine green), titanium pigment (e.g., titanium dioxide) or carbon pigment (e.g., carbon black, carbon yellow and carbon red).
  • ferric pigment e.g., iron black, iron yellow and iron red
  • phthalocyanine pigments e.g., phthalocyanine green blue and phthalocyanine green
  • titanium pigment e.g., titanium dioxide
  • carbon pigment e.g., carbon black, carbon yellow and carbon red
  • Other pigments conventionally used in the manufacture of synthetic quartz are intended to fall within the scope of the invention.
  • Chips appropriate for use in the combination include mirror chips, shell chips and metal flakes each of which can be derived from recycled materials.
  • Additives suitable for use in the combination according to the invention include alumina hydrate, tert-butyl, and promoter cobalt styrene.
  • the production process involves a progression through a number of systems and operations as follows: Raw materials preparation system ⁇ batching system ⁇ mixing system ⁇ distribution system ⁇ vacuum, vibration and pressing system ⁇ curing.
  • the improved synthetic quartz can be manufactured in panels, containers and other shapes limited only by available molds. Panels of the improved synthetic quartz are manufactured using a process that mixes the above materials in a pot in a vacuum, vibrating the mixture, pressing the mixed material into a desired shape and thickness, and letting it cure. [0021] Containers are manufactured using a production process that mixes the [0022] The temperature range during the curing period is 10-200 0 C, but applicants have determined that suitable temperature ranges are 15-35 0 C or 120-150 0 C depending on the composition of the mixture.
  • Resin Unsaturated polyester resin, available from Ashland Specialty Composite Polymers, 5200 Blazer Parkway, Dublin, OH 43017 or DSM; epoxy available, from CIBA Corporation: 540 White Plains Road, P.O. Box 2005, Tarrytown, 10591 , New York; polyurethane resin, available from Huntsman Advanced Materials, phenolic resin available from Plastics Engineering Company, of Sheboygan, Wl, Mitsui & Co. Ltd. in Japan, or Bakelite AG in Germany; acrylic resin available from Evalite International Co. Ltd., Suite 1001a, 10th, Tower 1 , Hong Kong.
  • Coupling agent F-methacryloxypropyltrimethoxysilane available from Zibo Xhuliang Rubber l/e Co., Ltd., located in China, under the brand name KH-570, Osi Specialties North America, located in South Charleston, WV, Dow Corning under the brand name Z-6030, Toray Group, located in Japan, under the brand name SH6030, or Anhui Herrman Impex Co., Ltd., located in China, under the brand name KBM-503.
  • Fiber Fiberglass, available from CPIC Fiberglass Chongqing Polycomp International Corp., Dadukou Dist., Chongqing, P.R. China.; carbon fiber, available from TOHO TENAX Co., Ltd., Kasumigaseki Common Gate West Tower, 3-2-1 Kasumigaseki, Chiyoda-ku, Tokyo, Japan 100-8585; basalt fiber, available from Hengdian Group Russia & Gold Basalt Fiber Co., No. 258, Songxing West Rd., Shanghai, Baoshan District, RR. China 200940; and boron fiber, available from Beijing Oriental New Materials Technology Co.
  • Example 1 Combine the ingredients indicated in Example 1 according to the given percentages. Deposit the mix onto the mold in as uniform a thickness as possible. Subject the molded material to a vacuum calibrated to facilitate removal of air bubbles from the mixture. Vibrate the mixture to further assist removal of air bubbles and to settle the material in the mold. Press the material to compact it to a density, which when cured, will have the desired physical properties. While continuing the press the material in the mold, cure the material at 10 0 C to create blanks. Finish the blanks by grinding the bottom side, turning them over, sanding the top side to a desired uniform thickness, and polishing. The finished product is a high density, super hard synthetic quartz panel.
  • Example 4 Combine the ingredients indicated in Examples 2 and 3 according to the given percentages. Manufacture the mixture into panels according to the procedures discussed above in connection with Example 1 , except that the mixture should be cured at 25 0 C. The finished product is a high density, super hard synthetic quartz panel.
  • Example 4
  • Example 4 Combine the ingredients indicated in Example 4 according to the given percentages. Manufacture the mixture into panels according to the procedures described above in connection with Example 1 , except that the mixture should be cured at 15 0 C. The finished product is a high density, super hard synthetic quartz panel.
  • Example 5 Combine the ingredients indicated in Example 5 according to the given percentages. Manufacture the mixture into panels according to the procedures described above in connection with Example 1 , except that the mixture should be cured at 35 0 C. The finished product is a high density, super hard synthetic quartz panel.
  • Example 8 Combine the ingredients indicated in Examples 6 and 7 according to the given percentages. Manufacture the mixture into panels according to the procedures described above in connection with Example 1 , except that the mixture should be heated to and cured at 120 0 C. The finished product is a high density, super hard synthetic quartz panel.
  • Example 8
  • the finished product is a high density, super hard synthetic quartz panel.
  • the finished product is a high density, super hard synthetic quartz panel. Performance:
  • synthetic quartz products according to the invention have physical properties superior to the conventional synthetic quartz stone product.
  • a very practical advantage conferred by the superior properties of synthetic quartz stone products manufactured according to the invention is that they are more resistant to breakage.
  • Prior art synthetic quartz stone products must be shipped on end, whereas the improved synthetic quartz stone products may be shipped horizontally.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Organic Chemistry (AREA)
  • Materials Engineering (AREA)
  • Structural Engineering (AREA)
  • Health & Medical Sciences (AREA)
  • Medicinal Chemistry (AREA)
  • Polymers & Plastics (AREA)
  • Compositions Of Macromolecular Compounds (AREA)

Abstract

La présente invention concerne une composition de quartz synthétique améliorée possédant une résistance à la traction, une résistance à la compression et une résistance à la flexion améliorées, et comprenant jusqu'à 90 % de pierre de quartz, de 5 à 90 % de poudre de quartz, de 0,1 à 20 % de résine, de 1 à 25 % de fibre, de 0,1 à 5 % d'un agent de couplage, de 0,1 à 5 % d'un agent de durcissement, jusqu'à 70 % d'éclats de verre, jusqu'à 70 % d'éclats de miroir, jusqu'à 5 % de pigment, jusqu'à 5 % d'éclats de coquillage, et jusqu'à 5 % de paillettes métalliques, en poids. La composition peut être produite sous forme de panneaux et de formes moulées telles que des contenants.
PCT/US2010/023781 2008-08-25 2010-02-10 Composition de quartz synthétique améliorée et son procédé de fabrication Ceased WO2010093714A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
US13/148,940 US20120283087A1 (en) 2008-08-25 2010-02-10 Synthetic quartz composition and production process therefor

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US12/368,562 US20100048772A1 (en) 2008-08-25 2009-02-10 Synthetic quartz composition and production process therefor
US12/368,562 2009-02-10

Publications (1)

Publication Number Publication Date
WO2010093714A1 true WO2010093714A1 (fr) 2010-08-19

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Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2630102A4 (fr) * 2010-10-19 2014-10-01 Lg Hausys Ltd Marbre acrylique artificiel à motif contenant des perles et son procédé de production
CN104193226A (zh) * 2014-08-31 2014-12-10 桂林理工大学 一种碳纤维增强石英合成石板材的制备方法
CN114956657A (zh) * 2022-05-30 2022-08-30 安徽弗仕通实业有限公司 一种石英石板材生产工艺

Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5043377A (en) * 1988-10-07 1991-08-27 Nippon Shokubai Kagaku Kogyo Company, Ltd. Granite-like artificial stone
US5280051A (en) * 1990-12-21 1994-01-18 Enichem Synthesis S.P.A. Composition for the production of artificial marble or granite
US6028127A (en) * 1994-10-14 2000-02-22 Mitsubishi Rayon Co., Ltd. Artificial marble and method for preparing it
US20010051674A1 (en) * 2000-04-06 2001-12-13 Fiorenzo Renzi Composition forming artificial marble or granite
US6517915B1 (en) * 1999-10-29 2003-02-11 Christopher T. Banus Composite stone surfacing with improved optical and wear resistance properties
US6989190B2 (en) * 2000-10-17 2006-01-24 General Electric Company Transparent polycarbonate polyester composition and process
US20080245476A1 (en) * 2005-11-10 2008-10-09 Henkel Ag & Co. Kgaa Silane-Crosslinking Adhesive, Sealant or Coating With a Silicic Acid Filler and Use Thereof

Patent Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5043377A (en) * 1988-10-07 1991-08-27 Nippon Shokubai Kagaku Kogyo Company, Ltd. Granite-like artificial stone
US5280051A (en) * 1990-12-21 1994-01-18 Enichem Synthesis S.P.A. Composition for the production of artificial marble or granite
US6028127A (en) * 1994-10-14 2000-02-22 Mitsubishi Rayon Co., Ltd. Artificial marble and method for preparing it
US6517915B1 (en) * 1999-10-29 2003-02-11 Christopher T. Banus Composite stone surfacing with improved optical and wear resistance properties
US20010051674A1 (en) * 2000-04-06 2001-12-13 Fiorenzo Renzi Composition forming artificial marble or granite
US6989190B2 (en) * 2000-10-17 2006-01-24 General Electric Company Transparent polycarbonate polyester composition and process
US20080245476A1 (en) * 2005-11-10 2008-10-09 Henkel Ag & Co. Kgaa Silane-Crosslinking Adhesive, Sealant or Coating With a Silicic Acid Filler and Use Thereof

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2630102A4 (fr) * 2010-10-19 2014-10-01 Lg Hausys Ltd Marbre acrylique artificiel à motif contenant des perles et son procédé de production
CN104193226A (zh) * 2014-08-31 2014-12-10 桂林理工大学 一种碳纤维增强石英合成石板材的制备方法
CN114956657A (zh) * 2022-05-30 2022-08-30 安徽弗仕通实业有限公司 一种石英石板材生产工艺

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