Field of the Invention

The present invention relates to the use of quartz of smaller than 0.1 to 0.3 mm particle size in order to obtain products with higher strength and better surface appearance in the production of composite stones.

Background of the Invention

In the composite stone production process, it is ensured to prepare composite stone by molding, pressing and curing the mixture of quartz and resin. When the coarse-grained quartz is used, the appearance of the quartz surface moves away from the appearance of natural stone, while the fine-grained quartz is used, a softer and more natural appearance is achieved. The fine particle sizes mentioned herein range from 0.1 to 0.3 mm. When using quartz with only 0.1 to 0.3 mm grain size, the best appearance, and the highest strength is achieved.

Quartz surface products have high strength values. According to the familiar applications in the state of the art are to improve the existing properties, to make the product even more durable, to obtain a softer appearance by using different sizes from the standard particle sizes used by each company in the market. 0.1-0.3 mm size quartz is used in the market and during the sizing of quartz, the particle size of 63-200 mm is also occured. There is a need to use the particle size of 63- 200 mm quartz to increase productivity.

In general, particle sizes of 0.1-0.3 mm, 0.3-0.7 mm, 0.6- 1.2 mm quartz are used in production processes. For this reason, products produced using only 0.1-0.3 mm size quartz are considered to have the most natural appearance and the highest strength. Summary of the Invention

The object of the present invention is to evaluate the thinner quartz (63-200 micrometer) formed in quartz sizing, to provide an alternative to 0.1 -0.3 mm quartz with supply shortage, to obtain products with higher strength and better surface appearance, and increase the flexural strength and impact resistance.

Detailed Description of the Invention

In order to attain the object of the present invention, “a composite stone production process with improved mechanical strength and surface properties " is shown in the attached figures. Of these figures:

Sekil 1 - This is a graphical presentation of the flexural strength results of samples produced using the formula 63-200 mm and the formula 63- 200 + 100-300 mm.

Sekil 2 - This is a graphical presentation of the impact resistance results of samples produced using the formula 63-200 mm and the formula 63- 200 + 100-300 mm.

Composite stone production process consists of mixing 90% quartz and 10% polyester resin, pouring the mixture into a mold and pressing it under vacuum with vibration and curing the compressed mixture by exothermic reaction at 100 ° C. The main difference of the subject of the invention in the production process against the state of the art is the use of 63-200 mm quartz in the mixture for the production of composite stones with higher strength and better surface appearance. In one implementation of the invention, quartz material having combined particle sizes in the form of the formula 63-200 mm + 100-300 mm is used.

Within the scope of the invention, the voids between the 100-300 mm sized particles used in production are filled. Filling the voids between the particles with small size quartz instead of thermoset resin provides a more natural and better surface. The distinguishing aspect of the process carried out by the invention is that instead of the micronized quartz used to fill the voids between the particles, quartz of 63-200 microns in size between 100-300 microns and micronized quartz is used. To summarize, first voids between 100-300 micron size are filled with 63- 200 micron size particles, then voids between 63-200 micron are filled using micronized quartz.

Within the scope of the invention, except the dimension of 0.1-0.3 mm, an evaluation of 63-200 mm quartz which is thinner in size is provided during quartz sizing and an alternative to dimension of 0.1-0.3 mm quartz which is difficult to supply is achieved. Thus, a more natural-appearance and higher strength product is obtained.

In traditional applications, quartz aggregates from the mine are broken and sieved and quartz sizes of 0.1-0.3 mm 0.3-0.7 mm 0.6-1.2 mm are obtained. It uses 0.1- 0.3 mm quartz in its marble-look fine granular products. Products produced using only 0.1-0.3 mm size quartz are the most natural-looking and highest strength products. However, within the scope of the present invention, it is preferred to use quartz thinner than 0.1 -0.3 mm in order to increase the strength and provide a more natural appearance. In addition to this, an increase of 10% is tried to be achieved in the mechanical strength values determined in the current implementations .

Within the scope of the invention, it is provided to value 63-200 mm quartz which is thinner in quartz refraction, except 0.1-0.3 mm dimension. Thus, an alternative to the quartz size of 0.1-0.3 mm, which has a supply shortage, will be obtained and a higher mechanical strength product with better surface appearance will be obtained.

Experimental Studies Within the scope of experimental studies carried out during the development of the invention; the efficiency of obtaining a thinner dimension less than 0.1 -0.3 mm was examined and it was determined whether whiteness of 0.1-0.3 mm would be obtained from the quartz aggregates, d10 d50 d90 values were determined with Malvern particle size analyzer device, sieve analysis studies were carried out, after the determined particle size distribution and color studies, the formula was determined in accordance with bolomey theorem and void test was done for this, sample studies were made in the prototype plant according to the determined formula and the optimum resin value was tried to be determined through the determined formula, prototype plant sample strength test, compactness, and surface quality optimization were studied.

1.1. QUALITY CONTROL OF RAW MATERIALS

Size verification of 63-200 mm quartz samples was carried out in the laboratory with Malvern particle size analyser device and color measurements were performed with a spectrophotometer. The results are presented in Tables 1 and 2.

Table 1. This is the particle size verification of a quartz sample with a size of 63- 200 mm.

.able 2. This is the color values of a quartz sample with a size of 63-200 mm.

1.2. FORMULATION STUDIES

After the raw material control tests were carried out, the method determination step was started. In order to find out how much resin is required for quartz with 63-200 mm dimension, the void amount was calculated by performing a void test. By using Bolomey theorem, it is determined how much resin will be used for 63- 200 mm quartz. Void test was performed first for quartz with a size of 63-200 mm .

1.2.1. VOID TEST

1.2.1.1. Void Test for Quartz Size 63-200 mm

2000 grams of 63-200 mm quartz is weighed. 20 grams of water is added. The reason for this process is that fine granules do not remain under the mixture and homogeneous mixture can be obtained. The void test cylinder with a volume of 1020 ml is tared and then filled with the aid of a clamping device. The cylinder filled with quartz is finally weighed. After the cylinder is filled with quartz mixture, it is filled with water until it appears on the surface and the amount of water added is recorded.

Cylinder _tare = 4066 grams

Quartz: 1482 grams

Water added: 367 grams

20 grams of water in a mixture of 2000 grams

...... x grams of water in a mixture of 1482 grams

x = 14.82 grams of water Total added water: 367 +14.82 = 381.82 grams of water is required to fill the void. Since the density of water is 1, the amount of water directly gives the volume of the void.

If d= m/v and if 1= 381, 82/V, V= 381,82 ml

381,82 ml void in 1020 ml container volume

...x..ml in 100 ml container volume

X = 381,82x100 / 1020 = 37.43% void.

1.2.2. BOLOMEY THEOREM

1.2.2.1. Formulation for Quartz Size 63-200 mm

As a result of the formula studies carried out in the laboratory, 63-200 63m size quartz was 59.6% by weight; filler 28% by weight; the resin was determined to be 12.3% by weight. 1.3. LABORATORY PROTOTYPE SAMPLE STUDIES

As a result of the formulation studies performed, prototype sample studies were started in the laboratory. Firstly, the formula containing fully 63-200 mm was studied. The mechanical test results of the stones performed with the formulas are presented in Table 3.

Table 3. Mechanical test results of laboratory samples performed by using 63-200 mm quartz.

After the prototype of Carola, Fairy White and Mocca Mousse products have been formed, 63-200 mm quartz was requested and standard control tests of incoming quartz samples were performed. The results are given in Table 4. Carola, Fairy White and Mocca Mousse products were tested in the plant for 63-200 mm dimension whose prototype was formed in the laboratory. The mechanical test results of the products produced are compared with the Belenco values and presented in Table 5.

Table 4. Quality control results of quartz with 63-200 mm size.

Table 5. This is a comparison of the stones produced with 63-200 mm quartz in the plant and Belenco production stones.

Flexural strength of Carola sample is 80,46 MPa in the standard formula, the impact strength is 10 joules; In the formula used 63-200 mm, the average flexural strength is 85.06 MPa and the impact strength is 10 joules. The flexural strength of Fairy White sample with the stones performed by the standard formula was measured 73.43 MPa, impact strength was 7.53 joule; the flexural strength with the stones performed by using 63-200 mm was measured as 85,30 MPa and the impact strength as 8,40 joules. The flexural strength of Mocca mousse sample was 80,66 MPa, impact strength 8,63 joule in the standard formula; In the formula used 63-200 mm, the average flexural strength is 86.04 MPa and the impact strength is average 9.76 joules. Compared to Belenco standard productions, the flexural strength and impact resistance increased while surface defects and dryness have been observed in the produced stones.

Due to the dense surface defect and dryness observed in the stones, it was decided to try by blending 63-200 and 100-300 mm in size. II. STAGE

63-200 mm and 100-300 mm quartz samples were firstly requested for the formulas to be formed by blending quartz with 63-200 mm and 100-300 mm size.

2.1. QUALITY CONTROL OF RAW MATERIALS

Dimension verification of 63-200 mm size quartz brought to the laboratory was performed with Malvern Particle Size Analyzer device and size verification of quartz size 100-300 mm were performed with sieve vibration machine. The results are presented in Tables 6 and 7. In addition, the color measurements of quartz were performed by spectrophotometer and the results were shown in Tables 8 and 9.

Table 6. This is the size verification of a quartz sample with a size of 63-200 mm.

Table 7. This is the size verification of a 100-300 mm quartz sample.

Table 8. This is the color values of a quartz sample with a size of 63-200 mm.

Table 9. The color values of the quartz sample of 100-300 mm.

2.2. FORMULATION STUDIES

After the raw material control tests were carried out, the method determination step was started. When 63-200 mm quartz and 100-300 mm quartz are blended, firstly the void test was performed and the void amount was calculated to determine how much resin is required. By using Bolomey theorem, it is determined how much resin will be used for 63-200 mm quartz. Void test was performed first for quartz with a size of 63-200 mm +100-300 mm. 2.2.1. VOID TEST

2.2.1.1. Void Test for Quartz Size 63-200 mm +100-300 mm

500 g of 63-200 mm and 1500 g of 100-300 mm are weighed. 20 g of water is added and mixed thoroughly. The void test cylinder is tared. The quartz is gradually placed in the cylinder and compacted. The added quartz weight is recorded. The balance is then reset and water is added. The added water is also recorded.

Cylinder _tare = 4066 grams

Quartz: 1543 grams

Water added: 351 grams

20 grams of water in a mixture of 2000 grams

...x... grams of water in a mixture of 1543 grams

x = 15.43 grams of water

Total added water: 351 +15.43 = 366.43 grams of water is required to fill the void. Since the density of water is 1, the amount of water directly gives the volume of the void.

If d = m / v, and if 1= 366,43/V V= 366,43 ml

If there is 366,43 ml void in the 1020 ml container volume

...x..ml in 100 ml container volume

X = 366,82x100/1020 = 35.92% void

2.2.2. BOLOMEY THEOREM

2.2.2.1. Formulation for Quartz with a Size of 100-300 mm +63-200 mm As a result of the formula studies carried out in the laboratory, it was determined for 63-200 mm sized quartz as 15.1%; Quartz with a size of 100-300 mm as 45.3; filler 27.9%; and the resin as 11.8%.

2.3. LABORATORY PROTOTYPE SAMPLE STUDIES

As a result of the formulation studies performed, prototype sample studies were started in the laboratory. The formula containing 63-200mm +100-300 formula was studied. The mechanical test results of the stones performed with the formulas are presented in Table 10.

Table 10. These are the mechanical test results of laboratory samples performed by using quartz with the size of 63-200mm +100-300mm

After the prototype sample was created, Fairy White and Mocca Mousse products were tested in the plant for 63-200mm +100-300 mm size. The quality control results of 63-200 -200mm size quartz used in production are presented in Table 11 and the quality control results of 100-300 mm size quartz are presented in Table 12. The mechanical test results of the products produced are presented in Table

13.

Table 11. These are the dimension of 63-200 mm quartz quality control results.

Table 12. These are quartz quality control results of 100-300 mm size.

Table 13. This is the comparison of the formula performed by using 63-200 mm + 100-300 mm formula, 63-200 mm formula and Standard Belenco formula in the plant.

The flexural and impact strength results of the stones produced with the formula 63-200 + 100-300 mm were measured to be in Fairy White sample average 79.84 MPa, flexural strength average of 8.23 joules; in the Mocca Mousse sample, the flexural strength was measured as average 80.22 MPa and the impact strength as 8.65 joules. The average flexural and impact strength test results of the stones obtained by formulas formed with different quartz sizes are given in Figure 2 and Figure 3. In the stones produced by using 63-200 + 100-300 mm it was observed that the mechanical properties decreased and dryness in plates and surface defects in the trial productions continued.

Within the scope of the invention, it is aimed to value the thinner 63-200 mm quartz formed in quartz sizing, except 100-300 mm size and to obtain a high strength product. In this way, an alternative to the quartz size of 100-300 mm which raises problems during the supplying, will be ensured. However, in the formula performed by using only 63-200 mm size, in the results of tests applied to slabs, mechanical properties improved while surface defects and cracks in the slabs were observed. In the slabs performed by using the formula 63-200 + 100- 300 mm surface defects and dryness were also observed. A low viscosity resin with high wetting properties was used to solve surface defects and dryness problems. In the R&D trials performed with the formulas developed by using 63- 200 + 100-300 mm quartz and high wetting resin, a smooth surface was obtained.