Synthetic resins or natural rubbers -- part of the class 520 ser – Synthetic resins – Processes of preparing a desired or intentional composition...
Patent
1992-11-27
1994-06-28
Michl, Paul R.
Synthetic resins or natural rubbers -- part of the class 520 ser
Synthetic resins
Processes of preparing a desired or intentional composition...
523171, C08L 6707, C09D 529
Patent
active
053247574
DESCRIPTION:
BRIEF SUMMARY
The present invention relates to resin-based artificial marble compositions which can be cast into articles possessing excellent translucency and a high resistance to degradation by hot water.
Hitherto, the manufacture of marble-like articles by casting or hot-compression molding has been known, in which a polymerizable composition is employed which is prepared by adding a glass filler, or aluminium hydroxide to an unsaturated polyester resin to form a resin matrix. An example of the former composition is found in JP-8052114, whilst an example of the latter can be found in JP-62246961.
However, these known compositions often only give unsatisfactory results when bath tubs or like articles are to be manufactured which require resistance to hot water. This is because, where aluminium hydroxide is used as a filler for artificial marble, it is found that interfacial peeling tends to occur between the unsaturated polyester resin matrix and the aluminium hydroxide filler when the article is brought into contact with hot water. This interfacial peeling seriously degrades the external appearance of the article due to whitening or opacifying of the surface thereof. Because of this, a glass filler has been so far generally used in artificial marble-like articles, such as bath tubs, kitchen work surfaces, wash hand basins or washstands, which are required to have a resistance to hot water. However, the machinability of marble-like articles, including cutting, drilling or polishing, depends greatly upon the hardness of the filler used. Aluminium hydroxide has a Mohs' scale of hardness of 3, whilst a glass filler is harder than the former, having a Mohs' scale of hardness of 6 Therefore, where a glass filler is used in manufactured marble-like articles, not only is much labour required but also some specialised tools are necessary for working and machining them. Additionally, in kneading a glass filler-containing polymerizable compound, the metal parts of the kneader are abraded by the glass filler and the resultant metal powder is introduced into the polymerizable compound thereby blackening the marble-like article formed therefrom. In order to avoid this problem, it is necessary to apply a coating of titanium or glass onto the parts of the kneader which are to be brought into contact with a glass filler.
On the other hand, it is also extremely difficult to form artificial marble-like bath tubs and the like, which are required to have excellent resistance to hot water, using aluminium hydroxide as a filler for the resin compound from which the artificial marble article is to be made. The reasons are twofold; (1) firstly there is the problem with the unsaturated polyester resin which is one of the essential materials for artificial marble and (2) secondly, there is the problem with the aluminium hydroxide. Regarding the former problem (1), where the water-proofness of the unsaturated polyester resin itself, for example, the water-absorption and the hydrolysis-resistance thereof, is insufficient when aluminium hydroxide is used as a filler, the resin itself tends to whiten when it is brought into contact with hot water. As for the latter problem (2), (a) interfacial peeling tends to occur between the unsaturated polyester resin and the aluminium hydroxide filler because of the poor adhesion between them caused by soluble soda impurities existing on the surface of the aluminium hydroxide and because of penetration of water into the interface therebetween, and (b) the soluble soda components which exist mainly on the surface of aluminium hydroxide as an impurity (such "soluble soda components" do not refer to the total soda content in the aluminium hydroxide) dissolve into water whereby either the aluminium hydroxide is dissolved in the resulting alkaline solution or else the unsaturated polyester resin is hydrolyzed by the same solution thereby to cause whitening of the resultant marble article.
The present inventors earnestly studied the above-mentioned problems and, as a result, have found that marble-like articles wit
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Dialog Information Services, File 351, World Patent Index 81-90, Dialog accession No. 87-345076/49, (Kyowa Gas Chem Ind), "Plastics cast--moulding, used for counter surfaces, etc.--is prepd. by adding a filler treated with a silane--coupling agent to a casting material", JP 62248610, A, 871029, 8749 (Basic).
Dialog Information Services, File 351, World Patent Index 81-90, Dialog accession No. 85-287700/46, (Nippon Shokubai Kagaku), "Marble--like article prepn. using unsatd., polyester, aluminium hydroxide and curing agent", JP 60199053, A, 851008, 8546 (Basic).
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Ishizaki Masashi
Matsuba Toshihiro
Ohkawa, deceased Jun
Alcan Chemicals Limited
Cain Edward
Michl Paul R.
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