FORM 2
THE PATENT ACT 1970
(39 OF 1970)
&
THE PATENT RULE , 2003
COMPLETE SPECIFICATION
(SECTION 10 & RULE 13)
TITLE OF THE WORK: PETPAPE

FIELD OF THE WORK:
The present invention relates to reduce the use of polyester film to be used as raw material in manufacturing process of quartz stone/ artificial or engineering stone .
BACKGROUND OF THE WORK:
Several technologies have been developed and used to manufacture artificial stone quartz or engineering stones. Polyester films are used as raw material of the artificial stone / quartz stone/ engineered stone to give it shape and strength at the final stage of manufacturUing process in the heated press.
US7923099B2 composition of acrylic artificial stone
describes manufacturing of artificial stone where in composition include about 0.1 to 5 parts by weight of the metallized polymer film particles, based on 100 parts by weight of the acrylic resin, and about 100 to 200 parts by weight of the inorganic filler, based on 100 parts by weight of the acrylic . resin. The metallized polymer film particles may include one or more metal layers on a surface of a polymer film. The metallized polymer film particles may have a particle size of about 0.001 to about 2.5 mm. A thickness of the polymer film may be about 30 µm to about 100 µm. A total thickness of the one or more metal layers may be about 1 µm to about 10 µm. The polymeric acrylic matrix may include a weight fraction of greater than or equal to about 65% of one or more acrylic acid compounds, and a weight fraction of less than or equal to about 35% of one or more polyacrylates. The one or more acrylic

acid compounds may include one or more of methacrylic acid, methyl methacrylate, ethyl methacrylate, isopropyl methacrylate, n-butyl methacrylate and/or 2-ethylhexyl methacrylate. The acrylic artificial stone article may further include artificial and/or genuine stone chips having a particle size of about 0.1 mm to about 5 mm. At least one of the above and other features and advantages may also be realized by providing a method of preparing an artificial stone, including providing an acrylic resin, metallized polymer film particles, and an inorganic filler; and combining the acrylic resin, metallized polymer film particles, and the inorganic filler to form a composition. The method of preparing an artificial stone may further include forming the composition into a predetermined shape, and curing the composition to form a solid surface article.
EUROPEAN PATENT (EP 3180395A1) discusses Laminates containing coated polyester films :
A bonding material is described that is well suited to bonding polymer films, such as polyester films, to other substrates. In one embodiment, for instance, the bonding material can be used to bond a polyester film to a polypropylene article. The bonding material generally comprises an adhesive agent combined with a cross-linking agent. The adhesive agent may comprise a carboxylic acid modified polypropylene homopolymer, copolymer or ionomer. In one embodiment, the adhesive agent comprises a polypropylene modified by an unsaturated dicarboxylic acid anhydride. The cross-linking agent, on the other hand, may comprise an oxazoline polymer.

It is about a coating that can be applied to a polyester film for improving adhesion between the polyester film and a second polymeric layer. The invention is particularly effective when utilized to bond a polyethylene terephthalate sheet to a polypropylene article. Of particular advantage, the adhesive coating is particularly resistant to degradation caused by weathering, and is capable of retaining a relatively large amount of its initial bond strength between the two layers even after exposure for many hours to an environment at a relatively high temperature and/or at relatively high humidity levels.. It has demonstrated excellent adhesion to polyester films that contain various fillers. For example, in one embodiment, the polyester film may contain a significant amount of while pigment particles, such as barium sulfate particles or titanium dioxide particles. The white pigment particles are added to the film, in one embodiment, to provide the film with a white color, such that the film has a Berger whiteness of greater than 70, such as greater than 75, such as greater than 80. The white pigment particles are included in the film so that the film has desired weatherability, reflectance, or appearance properties.
OBJECT OF THE WORK:
The main object of the invention is to reduce use of Polyester film to minimum extent in process of manufacturing of artificial stone/ quartz stone & engineered stone without affecting its solidity and strength to make it cost effective and environmental friendly.

KNOWN ART:
To manufacture artificial, quartz powder, resin, pigments, Alumina trihydrate etc raw materials are mixed into mixture and then put into a steel frame. Then mixture is covered with Polyester Film of 127.8 gsm from both the sides and put into a heated chamber of 110 degree Celsius and pressed from both the sides (upper & lower) and proceed further at calibration stage to check slab's thickness, polishing and make surface smooth and shining free from waste particles and cut into the desired size.
In present art, in whole process of manufacturing quartz stone, 127.8 gsm Polyester film is mandatory and can be used only once in process of coating. Again handling and disposing of waste of Polyester film is big task as it is hazardous to the environment and is costly affair for the industries.
PROCESS OF THE WORK:
The present invention is consisting of 3 main ingredients which are processed in very innovative manner. The 3 basic ingredients with quantity are as under;
1) Paper (width 800 mm to 2200 mm)
2) Polyester film (width 800 mm to 2200mm / thickness 15 gsm to 60 gsm)
3) Adhesive (Acrylic - 2 gsm to 20 gsm)
In present process thickness of Polyester film ie 127.8 gsm is reduce to minimum ie 15gsm and maximum 60gsm ; laminated with Paper in process

of manufacturing of artificial stone. The details of process of working are given in steps as under :
STEPS:
1. In high width gravure coating cum lamination machine, Polyester film of 15gsm thick loaded on unwinder shaft, acrylic adhesive of 2gsm loaded in coating system. Polyester film is passed through gravure coating station into the heated chamber / tunnel with 100 degree Celsius. Further acrylic adhesive is cured and coated with polyester film in lamination station. The acrylic adhesive coated with polyester film is laminated to the Kraft paper to give it backing and strength termed as ' PETPAPE'. The description of step is also illustrated in FIG 1 where in pink color describe the position of adhesive try, polyester films passing through tunnel under heated process and paper polyester lamination station.
2. Laminated material made of acrylic adhesive with polyester film ie PETPAPE is again processed for release coating to ease removal of material during manufacturing process of artificial / quartz stone to prepare solid surface after coming out from the heated compressed further vacuumed and pressed.
3. After release coat is done, the PETPAPE is taken to finishing stage
where it is silted into the required width and length.

4. In sitting cum rewinding machine, Petpape is loaded on the unwinder, edge is silted for removal of unwanted waste. It is again used on solid surface to re-wind and further process for quality control.
The above process of PETPAPE is materialized as final product and more particularly describe in Fig 2 where is one final product is illustrated and layers /component of PETPAPE

CLAIMS:
I/We claim, process mythology as well as product patent.
l.Use of paper, polyester film and acrylic adhesive to make Petpape to be used as raw material in manufacturing of artificial stone.
2. Process of stage of blending of paper, polyester film and acrylic adhesive in proportion demonstrated in Step 1 and step 2 to prepare Petpape