# US 10,766,815 B2 · Engineered stone and manufacturing method thereof

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- Number: US 10,766,815 B2
- Document ID: US10766815B2
- Status: Granted
- Kind: B2
- Application number: 15/807,673
- Filed: 2017-11-09
- Published: 2018-06-28
- Granted: 2020-09-08
- Earliest claimed: 2016-12-23
- Assignees: Lotte Advanced Materials Co., Ltd.
- Applicants: Lotte Advanced Materials Co., Ltd.
- Inventors: Heecheol Lee; Cheol-Yeon Hwang; Kyunghwan Kim; Seul-Gi Bae; Changho Son; Sung Jin An
- Web page: https://patentgrep.com/patent/US10766815B2

## CPC

- C04B 26/18: Polyesters; Polycarbonates
- B29C 43/56: Compression moulding under special conditions, e.g. vacuum
- B29C 67/244: {by vibrating the composition before or during moulding}
- C04B 14/00: Use of inorganic materials as fillers, e.g. pigments, for mortars, concrete or artificial stone; Treatment of inorganic materials specially adapted to enhance their filling properties in mortars, concrete or artificial stone (expanding or defibrillating materials C04B20/00)
- C04B 14/005: {Inorganic fillers with a shape other than granular or fibrous (carbon nanotubes C04B14/026)}
- C04B 16/00: Use of organic materials as fillers, e.g. pigments, for mortars, concrete or artificial stone; Treatment of organic materials specially adapted to enhance their filling properties in mortars, concrete or artificial stone
- C04B 18/022: {agglomerated by an organic binder}
- C09K 11/025: {non-luminescent particle coatings or suspension media}
- B29C 2043/563: {combined with mechanical pressure, i.e. mould plates, rams, stampers}
- B29K 2067/06: {Unsaturated polyesters}
- B29K 2105/24: crosslinked or vulcanised
- B29K 2509/08: Glass
- B29K 2995/0018: having particular optical properties, e.g. fluorescent or phosphorescent
- B29K 2995/0026: Transparent
- C04B 2103/54: Pigments; Dyes
- C04B 2111/00965: {for household applications, e.g. use of materials as cooking ware}
- C04B 2111/54: Substitutes for natural stone, artistic materials or the like
- C04B 2111/542: {Artificial natural stone}
- C04B 2111/807: {Luminescent or fluorescent materials}
- C04B 2111/82: Coloured materials
- C04B: LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE {(roofing granules E04D7/005)}; CERAMICS (devitrified glass-ceramics C03C10/00); REFRACTORIES; TREATMENT OF NATURAL STONE
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- C09K: MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
- B29K: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR {MOULDS, } REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS

## Abstract

An engineered stone includes a light transmitting mother material (I) and a phosphorescent chip (II). The light transmitting mother material (I) includes about 7 wt % to about 12 wt % of an unsaturated polyester resin (A), about 88 wt % to about 93 wt % of a silica-containing compound (B) and about 0.01 part by weight to about 1 part by weight of an organic/inorganic pigment (C) based on about 100 parts by weight of the unsaturated polyester resin (A). The phosphorescent chip (II) includes about 8 wt % to about 15 wt % of an unsaturated polyester resin (A′), about 85 wt % to about 92 wt % of a silica-containing compound (B′) and about 2 parts by weight to about 10 parts by weight of a phosphorescent pigment (D) based on about 100 parts by weight of the unsaturated polyester resin (A′).

## Claims

### Claim 1

An engineered stone, comprising
a light transmitting mother material (I) and a phosphorescent chip (II),
wherein the light transmitting mother material (I) includes about 7 wt % to about 12 wt % of an unsaturated polyester resin (A) and about 88 wt % to about 93 wt % of a silica-containing compound (B) based on a total amount of the unsaturated polyester resin (A) and the silica-containing compound (B) of the light transmitting mother material (I),
the light transmitting mother material (I) further includes about 0.01 part by weight to about 1 part by weight of an organic/inorganic pigment (C) based on about 100 parts by weight of the unsaturated polyester resin (A),
the phosphorescent chip (II) includes about 8 wt % to about 15 wt % of an unsaturated polyester resin (A′) and about 85 wt % to about 92 wt % of a silica-containing compound (B′) based on a total amount of the unsaturated polyester resin (A′) and the silica-containing compound (B′) of the phosphorescent chip (II),
the phosphorescent chip (II) further includes 2 parts by weight to 5 parts by weight of a phosphorescent pigment (D) based on 100 parts by weight of the unsaturated polyester resin (A′), and
the silica-containing compound (B′) includes about 20 wt % to about 30 wt % of a silica powder (b1′) based on a total amount of the phosphorescent chip (II).

### Claim 2 (depends on 1)

The engineered stone of claim 1, wherein the silica-containing compound (B) includes a silica powder (b1), a silica sand (b2), and a quartz chip (b3).

### Claim 3 (depends on 2)

The engineered stone of claim 2, wherein an average particle diameter of the silica powder (b1) is greater than about 0 μm and less than or equal to about 45 μm, an average particle diameter of the silica sand (b2) is greater than or equal to about 0.1 mm and less than about 1.2 mm, and an average particle diameter of the quartz chip (b3) is greater than or equal to about 1.2 mm and less than or equal to about 6.0 mm.

### Claim 4 (depends on 2)

The engineered stone of claim 2, wherein the light transmitting mother material (I) includes:
the silica powder (b1) in an amount of about 20 wt % to about 30 wt % based on a total amount of the light transmitting mother material (I),
the silica sand (b2) in an amount of about 35 wt % to about 45 wt % based on a total amount of the light transmitting mother material (I), and
the quartz chip (b3) in an amount of about 10 wt % to about 30 wt % based on a total amount of the light transmitting mother material (I).

### Claim 5 (depends on 1)

The engineered stone of claim 1, wherein the silica-containing compound (B′) further includes silica sand (b2′).

### Claim 6 (depends on 5)

The engineered stone of claim 5, wherein an average particle diameter of the silica powder (b1′) is greater than about 0 μm and less than or equal to about 45 μm and an average particle diameter of the silica sand (b2′) is greater than or equal to about 0.1 mm and less than about 1.2 mm.

### Claim 7 (depends on 5)

The engineered stone of claim 5, wherein the phosphorescent chip (II) includes the silica sand (b2′) in an amount of about 60 wt % to about 70 wt % based on a total amount of the phosphorescent chip (II).

### Claim 8 (depends on 1)

The engineered stone of claim 1, wherein the light transmitting mother material (I) and the phosphorescent chip (II) each further independently include a curing agent, a curing accelerator, and/or a cross-linking agent.

### Claim 9 (depends on 8)

The engineered stone of claim 8, wherein the cross-linking agent is a silane-based cross-linking agent.

### Claim 10 (depends on 1)

The engineered stone of claim 1, wherein the engineered stone has a diffuse transmittance of greater than or equal to about 6.0% and maintains luminance of greater than or equal to 7.0 mcd/m2 after one hour.

### Claim 11 (depends on 1)

The engineered stone of claim 1, wherein the phosphorescent chip (II) is an amorphous phosphorescent chip.

### Claim 12

A method for manufacturing an engineered stone, comprising
preparing a phosphorescent resin composition (ii) including about 8 wt % to about 15 wt % of an unsaturated polyester resin (A′), about 85 wt % to about 92 wt % of a silica-containing compound (B′), and a phosphorescent pigment (D), wherein the phosphorescent pigment (D) is included in an amount of 2 parts by weight to 5 parts by weight based on 100 parts by weight of the unsaturated polyester resin (A′), and the silica-containing compound (B′) includes about 20 wt % to about 30 wt % of a silica powder (b1′) based on a total amount of the phosphorescent resin composition (ii);
dispersing the phosphorescent resin composition (ii) using a dispersing equipment;
vacuum-vibration-compression molding the phosphorescent resin composition (ii) dispersed to have a predetermined shape and molding it into a sheet having a phosphorescence effect;
crushing the sheet having the phosphorescence effect to prepare a phosphorescent chip (II);
preparing a light transmitting resin composition (i) including about 7 wt % to about 12 wt % of an unsaturated polyester resin (A) and about 88 wt % to about 93 wt % of a silica-containing compound (B) based on a total amount of the unsaturated polyester resin (A) and the silica containing compound (B) of the light transmitting resin composition, and further including about 0.01 part by weight to about 1 part by weight of an organic/inorganic pigment (C) based on about 100 parts by weight of the unsaturated polyester resin (A′);
mixing the light transmitting resin composition (i) with the phosphorescent chip (II) to prepare an engineered stone mixture;
dispersing the engineered stone mixture using a dispersing equipment to have a predetermined shape; and
vacuum-vibration-compression molding a uniformly distributed engineered stone mixture to manufacture an engineered stone.

### Claim 13 (depends on 12)

The method of claim 12, wherein the silica-containing compound (B) includes a silica powder (b1) having an average particle diameter of greater than about 0 μm and less than or equal to about 45 μm, a silica sand (b2) having an average particle diameter of greater than or equal to about 0.1 mm and less than about 1.2 mm, and a quartz chip (b3) having an average particle diameter of greater than or equal to about 1.2 mm and less than or equal to about 6.0 mm, and
the silica powder (b1) is included in an amount of about 20 wt % to about 30 wt % based on a total amount of the light transmitting resin composition (i), the silica sand (b2) is included in an amount of about 35 wt % to about 45 wt % based on a total amount of the light transmitting resin composition (i), and the quartz chip (b3) included in an amount of about 10 wt % to about 30 wt % based on a total amount of the light transmitting resin composition (i).

### Claim 14 (depends on 12)

The method of claim 12, wherein the silica-containing compound (B′) includes a silica powder (b1′) having an average particle diameter of greater than about 0 μm and less than or equal to about 45 μm and a silica sand (b2′) having an average particle diameter of greater than or equal to about 0.1 mm and less than about 1.2 mm, and
the silica sand (b2′) is included in an amount of about 60 wt % to about 70 wt % based on a total amount of the phosphorescent resin composition (ii).