WO2009044417A1 - Agglomerated material for floorings and coverings, as well as a method for obtaining the same - Google Patents
Agglomerated material for floorings and coverings, as well as a method for obtaining the same Download PDFInfo
- Publication number
- WO2009044417A1 WO2009044417A1 PCT/IT2007/000696 IT2007000696W WO2009044417A1 WO 2009044417 A1 WO2009044417 A1 WO 2009044417A1 IT 2007000696 W IT2007000696 W IT 2007000696W WO 2009044417 A1 WO2009044417 A1 WO 2009044417A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- slabs
- resin
- agglomerated material
- microspheres
- quartz
- Prior art date
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
-
- 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
- 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
Definitions
- the present invention describes an agglomerated material for floorings and coverings comprising a mixture of unfinished stony material, microspheres and glass powder, colorants and mica, a binder preferably consisting of a resin and a filler preferably consisting of white quartz, where the unfinished stony material is mixed with these components in powder, granular or similar form.
- L The present invention also refers to a method for the industrial production of tiles, slabs and blocks made from the agglomerated material according to this invention.
- the present invention primarily applies to the production of floorings and coverings for indoor and outdoor applications for use in the construction industry.
- a further use of the agglomerated material would be a metallized embodiment for use in the production of kitchen worktops, tables and other items of furniture.
- One of the known production methods consists of several stages starting with the crushing of the basic material comprising the agglomerate.
- the crushed material is mixed with a hot polymerizing resin to form a paste which is then moulded under vacuum using vibrocompression to produce slabs of the shape required.
- the resinous material in the slabs is hardened or hot polymerized.
- the slabs of material are polished and then cut to size, chamfered, thicknessed and countersunk. It should be noted that the percentage of resin used in this type of mix is of crucial importance and needs to be chosen with considerable care and precision.
- the slab will be too soft and will have a closed, honeycomb structure which will not allow any air trapped in the paste to escape during the subsequent vacuum-vibrocompression moulding stage. If, on the other hand, the amount of resin used is insufficient, the resulting paste will be too dry, have a poor consistency and will not bond sufficiently during vibrocompression moulding.
- One of the known methods for increasing the hardness and wear resistance of slabs of agglomerated material is to add a very fine silica powder or sand to the paste.
- the silica does not impregnate the resin but acts a filler and at the same time enables a reduction in the quantity of resin necessary.
- Another method known to specialists in the sector involves the production of agglomerated material in blocks. Once the resin has been polymerized and the agglomerated material hardened, the blocks are cut into slabs to form floor or wall tiles or made-to-measure components such as steps, bathroom surfaces, kitchen tops and window sills.
- This type of agglomerated material has good mechanical characteristics which make it suitable for walling and flooring applications outdoors. However, it does have a drawback in that it has an opaque, non-reflecting surface and is not therefore suitable for enhancing the appearance of architectural features or creating a sense of space. Partially reflecting agglomerated material has the drawback that it does not maintain its gloss over a long enough period of time. A further drawback is that slabs which are cut from a block require sanding and polishing, two operations which can sometimes make the machined surfaces opaque.
- Crystobalite is a rare crystalline mineral occurring naturally as silica dioxide or silica. This mineral has a white-yellowish, glassy appearance and crystallizes in the tetragonal system; it does not have individual split crystallites but groups of spheroidal shape.
- Crystobalite is found in igneous rock and traces have been found in lunar rocks and meteorites.
- Silica sands, silica and crystobalite are recognised as improving the appearance of the final product but are all harmful to health, not to the final users of wall and floor coverings, but rather to those involved in the manufacturing processes and laying the material. All these materials are health hazards and the source of a serious disease called silicosis.
- This disease is caused by prolonged exposure to crystalline silica dioxide which occurs naturally in quartz, chalcedony and opal. Those at risk are industrial workers exposed to airborne concentrations higher than 1%.
- the hazard level depends on the percentage level of crystalline silica dioxide in the air inhaled and the length of exposure.
- the purpose of the present invention is to eliminate or significantly reduce the disadvantages of the known method by providing an agglomerated material comprising a base made from stony material, a binding agent preferably consisting of a resin and a filler preferably consisting of glass powder, glass microspheres and white quartz powder.
- the agglomerated material is used to make slabs, tiles or blocks which have surfaces reflecting light in multiple directions and a product which is generally whiter than traditional products.
- the present invention also includes a method for manufacturing slabs and blocks of metallized agglomerated material according to the invention.
- the agglomerated material described in the present invention consists of a mixture comprising 50 to 70% white quartz, 20 to 30% glass powder, 0.5 to 2% microspheres and 8 to 10% resin and additives.
- the microspheres are made from glass and have a granulometry of approximately 0.15 to 0.25 mm.
- the agglomerated material according to the present invention even though it contains no silica, silica powder or crystobalite, has excellent physical and mechanical characteristics. It has an exceptionally glossy sheen and is very white.
- the slabs produced in this way are whiter than those produced with conventional methods.
- the glossy slabs obtained with this process would be suitable for use in churches, museums and other imposing public buildings. They could also be used as table tops, kitchen worktops and floor and walling tiles.
- Slabs of metallized agglomerated material made according to the present invention could be cut to size without losing their glossy sheen or whiteness. No further surface polishing would be needed. This material has an exceptional aesthetic appeal and at the same time is simpler and easier to prepare and install.
- This metallized agglomerated material can withstand high breaking loads and is very resistant to scratching and corrosion particularly by acid.
- a further purpose of this invention is to provide a production method for manufacturing slabs of metallized agglomerated material in preset sizes.
- the production method employs automated machinery where one or more computers control the various steps in the method.
- the first step of the method consists of the crushing of the stony base material.
- the crushed stone is mixed with quartz, glass microspheres and glass powder in a special mixing machine.
- a suitable binder and a colorant are added to this mixture.
- the binder could be any suitable resin and in a preferred embodiment would be a polymer resin.
- the product mixture is poured into the mould of a press where a pressing force is applied to the product.
- This combined with the activation of a vibrating device and a vacuum device forms the slab into a preset shape, usually square, of a predefined thickness and density.
- the slab is conveyed into an oven where it hardens, thanks to the action of the chemical additives, at a preset temperature and for a suitably selected period of time.
- the slab leaves the oven and is conveyed to the work stations downstream for further treatment.
- Treatment could consist of polishing on one or both faces, cutting to size, chamfering, thicknessing and countersinking. After these operations the slab is conveyed to the waxing, drying and packing stations.
- the method described above enables the continuous production of agglomerated material slabs precisely conforming to the lengths, widths and thicknesses specified and having a glossy sheen and a brilliant white colour.
- a further advantage of agglomerated materials is that they have a high resistance to atmospheric and chemical corrosion and also to wear and scratching.
- the synthetic tiles and slabs manufactured from this material are therefore highly durable and their glossy sheen remains unchanged with the passing of time.
- the next section describes a non-limiting example formulation of the agglomerated mixture according to the invention used to produce the slabs employing the method described above.
- the UP 205/14 resin consists of the following materials:
- the mixture used in one embodiment of the agglomerated material according to the present invention could contain inclusions of various types such as fragments of metal and wood in addition to the polymerizing catalysts and accelerants.
Abstract
An agglomerated material used in the production of slabs, tiles and blocks for floorings and coverings. The material consists of a mixture comprising 50 to 70% white quartz, 20 to 30% glass powder, 0.5 to 2% microspheres and 8 to 10% resin and additives. The microspheres are made from glass and have a granulometry of approximately 0.15 to 025 mm.
Description
"AGGLOMERATED MATERIAL FOR FLOORINGS AND COVERINGS, AS
WELL AS A METHOD FOR OBTAINING THE SAME"
**********
TECHNICAL FIELD The present invention describes an agglomerated material for floorings and coverings comprising a mixture of unfinished stony material, microspheres and glass powder, colorants and mica, a binder preferably consisting of a resin and a filler preferably consisting of white quartz, where the unfinished stony material is mixed with these components in powder, granular or similar form. L The present invention also refers to a method for the industrial production of tiles, slabs and blocks made from the agglomerated material according to this invention.
The present invention primarily applies to the production of floorings and coverings for indoor and outdoor applications for use in the construction industry. A further use of the agglomerated material would be a metallized embodiment for use in the production of kitchen worktops, tables and other items of furniture.
BACKGROUND ART Agglomerated materials consisting of various mixtures of marble, granite, quartz, natural stone and silica sands agglomerated to obtain a synthetic material for use as floor and wall coverings have been known for some time.
Frequent attempts have been made to give the surface of this material a glossy sheen intended to create a pleasing appearance and an enhanced visual impact especially in applications in large open spaces.
These attempts, consisting mainly of adding colorants to the basic mixture, have not however produced a product with a lasting glossy finish or a glossy sheen which is distributed uniformly over the entire surface of the agglomerated material treated in this way. It would be particularly advantageous to be able to produce a glossy stone- based agglomerated material with a uniform colour and granulometry whose proportions could also be precisely specified at the outset. It would also be
advantageous if this material had isotropic reflecting properties, features which are not common in natural stone.
One of the known production methods consists of several stages starting with the crushing of the basic material comprising the agglomerate. The crushed material is mixed with a hot polymerizing resin to form a paste which is then moulded under vacuum using vibrocompression to produce slabs of the shape required. Finally, the resinous material in the slabs is hardened or hot polymerized.
After production with this method, the slabs of material are polished and then cut to size, chamfered, thicknessed and countersunk. It should be noted that the percentage of resin used in this type of mix is of crucial importance and needs to be chosen with considerable care and precision.
If the amount of resin is too high, the slab will be too soft and will have a closed, honeycomb structure which will not allow any air trapped in the paste to escape during the subsequent vacuum-vibrocompression moulding stage. If, on the other hand, the amount of resin used is insufficient, the resulting paste will be too dry, have a poor consistency and will not bond sufficiently during vibrocompression moulding.
One of the known methods for increasing the hardness and wear resistance of slabs of agglomerated material is to add a very fine silica powder or sand to the paste. In this case the silica does not impregnate the resin but acts a filler and at the same time enables a reduction in the quantity of resin necessary.
Another method known to specialists in the sector involves the production of agglomerated material in blocks. Once the resin has been polymerized and the agglomerated material hardened, the blocks are cut into slabs to form floor or wall tiles or made-to-measure components such as steps, bathroom surfaces, kitchen tops and window sills.
This type of agglomerated material has good mechanical characteristics which make it suitable for walling and flooring applications outdoors. However, it does have a drawback in that it has an opaque, non-reflecting surface and is not therefore suitable for enhancing the appearance of architectural features or creating a sense of space. Partially reflecting agglomerated material has the drawback that it does not maintain its gloss over a long enough period of time.
A further drawback is that slabs which are cut from a block require sanding and polishing, two operations which can sometimes make the machined surfaces opaque.
In order to increase surface gloss and sheen, it is general practice to include resins, additives, colorants, silica powders, silica sands and a special material called crystobalite in the raw materials used to make agglomerate pastes.
Crystobalite is a rare crystalline mineral occurring naturally as silica dioxide or silica. This mineral has a white-yellowish, glassy appearance and crystallizes in the tetragonal system; it does not have individual split crystallites but groups of spheroidal shape.
Crystobalite is found in igneous rock and traces have been found in lunar rocks and meteorites.
Silica sands, silica and crystobalite are recognised as improving the appearance of the final product but are all harmful to health, not to the final users of wall and floor coverings, but rather to those involved in the manufacturing processes and laying the material. All these materials are health hazards and the source of a serious disease called silicosis.
This disease is caused by prolonged exposure to crystalline silica dioxide which occurs naturally in quartz, chalcedony and opal. Those at risk are industrial workers exposed to airborne concentrations higher than 1%.
The highest risks occur in the manufacture and cutting of slabs and cladding tiles made from agglomerated materials containing silica, silica powders and crystobalite.
The hazard level depends on the percentage level of crystalline silica dioxide in the air inhaled and the length of exposure.
DISCLOSURE OF INVENTION
The purpose of the present invention is to eliminate or significantly reduce the disadvantages of the known method by providing an agglomerated material comprising a base made from stony material, a binding agent preferably consisting of a resin and a filler preferably consisting of glass powder, glass microspheres and white quartz powder. The agglomerated material is used to make slabs, tiles or
blocks which have surfaces reflecting light in multiple directions and a product which is generally whiter than traditional products.
This purpose is fulfilled by the agglomerated material described in the present invention and characterised in the main claims below. The dependent claims describe a preferred embodiment of the invention.
The present invention also includes a method for manufacturing slabs and blocks of metallized agglomerated material according to the invention.
This method is described in claim 5.
The dependent claims to claim 5 describe a preferred embodiment of the manufacturing method according to the invention.
The agglomerated material described in the present invention consists of a mixture comprising 50 to 70% white quartz, 20 to 30% glass powder, 0.5 to 2% microspheres and 8 to 10% resin and additives.
In a preferred embodiment of the invention the microspheres are made from glass and have a granulometry of approximately 0.15 to 0.25 mm.
The agglomerated material according to the present invention, even though it contains no silica, silica powder or crystobalite, has excellent physical and mechanical characteristics. It has an exceptionally glossy sheen and is very white.
The slabs produced in this way are whiter than those produced with conventional methods.
The glossy slabs obtained with this process would be suitable for use in churches, museums and other imposing public buildings. They could also be used as table tops, kitchen worktops and floor and walling tiles.
Slabs of metallized agglomerated material made according to the present invention could be cut to size without losing their glossy sheen or whiteness. No further surface polishing would be needed. This material has an exceptional aesthetic appeal and at the same time is simpler and easier to prepare and install.
This metallized agglomerated material can withstand high breaking loads and is very resistant to scratching and corrosion particularly by acid. A further purpose of this invention is to provide a production method for manufacturing slabs of metallized agglomerated material in preset sizes.
The production method employs automated machinery where one or more computers control the various steps in the method. The first step of the method consists of the crushing of the stony base material.
In the second step of the method the crushed stone is mixed with quartz, glass microspheres and glass powder in a special mixing machine. A suitable binder and a colorant are added to this mixture.
The binder could be any suitable resin and in a preferred embodiment would be a polymer resin.
In the third method step the product mixture is poured into the mould of a press where a pressing force is applied to the product. This combined with the activation of a vibrating device and a vacuum device forms the slab into a preset shape, usually square, of a predefined thickness and density.
After this step the slab is conveyed into an oven where it hardens, thanks to the action of the chemical additives, at a preset temperature and for a suitably selected period of time.
The slab leaves the oven and is conveyed to the work stations downstream for further treatment. Treatment could consist of polishing on one or both faces, cutting to size, chamfering, thicknessing and countersinking. After these operations the slab is conveyed to the waxing, drying and packing stations. The method described above enables the continuous production of agglomerated material slabs precisely conforming to the lengths, widths and thicknesses specified and having a glossy sheen and a brilliant white colour.
In addition to the polymerizing catalysts and accelerants added to the mixture employed with this method, it would also be possible to add brass, aluminium, alloy or other metallic components to the basic paste mixture in order to produce special optical effects and other types of appearance.
A further advantage of agglomerated materials is that they have a high resistance to atmospheric and chemical corrosion and also to wear and scratching. The synthetic tiles and slabs manufactured from this material are therefore highly durable and their glossy sheen remains unchanged with the passing of time.
The next section describes a non-limiting example formulation of the agglomerated mixture according to the invention used to produce the slabs employing the method described above.
DESCRIPTION OF AN EXAMPLE EMBODIMENT
*****
The example described below indicates the components of the agglomerated material according to the invention and their percentages by weight of the total weight of a material sample and where the formula is that for a single press:
The UP 205/14 resin consists of the following materials:
The embodiments of the invention described above are intended as examples only.
The invention is in no way limited to these embodiments and includes all the possible modifications and variants which enter within the terms of this invention and the claims below.
For example, the mixture used in one embodiment of the agglomerated material according to the present invention could contain inclusions of various types
such as fragments of metal and wood in addition to the polymerizing catalysts and accelerants.
The invention as described above refers to a preferred embodiment which is non-limiting. Clearly the invention includes the numerous possible variants which are technically equivalent.
Claims
1 . An agglomerated material used for the production of slabs, tiles or blocks for floorings and coverings, consisting of a mixture wherein the mixture consists of 50 to 70% white quartz, 20 to 30% glass powder, 0.5 to 2% microspheres and 8 to 10% resin and additives.
2 . An agglomerated material used for the production of slabs according to the foregoing claim 1 wherein the microspheres are made from glass and have a granulometry of approximately 0.15 to 0.25 mm.
3 . An agglomerated material according to the foregoing claims 1 and 2 wherein the resin is a polyester-based resin.
4. An agglomerated material according to the foregoing claims from 1 to 3 wherein the quartz used has a white colour.
5 . A method for the production of slabs made from the agglomerated material according to the foregoing claims wherein the method consists of a step where the crushed stony base material and inert fillers are mixed with a binder, a step where the material is pressed and vibrocompressed under vacuum, a step where the material is heated in an oven to a preset temperature for a preset time in order to catalyse the binder, and wherein the material comprises a mixture consisting of 50 to 70% white quartz, 20 to 30% glass powder, 0.5 to 2% microspheres and 8 to 10% resin and additives and wherein the purpose of the method is to produce slabs, tiles and blocks of a high quality and of a white colour.
6. A method according to claim 5 wherein the slabs leaving the firing step are subject to polishing, cutting, chamfering, thicknessing and countersinking operations in various combinations or as single operations.
7 . A method according to claim 5 wherein the mixture comprises total colour 3.00% (15.00 kg.), UP 205/14 resin 9.3% (46.4 kg.), Kalamaden quartz with 0.1/0.3 mm granulometry 48.5% (242 kg.), Kalamaden quartz with 0.3/0.5 mm granulometry 15,6% (78 kg.), microspheres of 0.15-0.25 mm 1.0% (5 kg.), PIN 327 glass powder 30 micron 25.6% (128 kg.), for a total weight of 514.40 kg.
8. A method according to claim 5 wherein the UP 205/14 resin comprises the following materials: catalyst 2.21% (1.027 kg.), MEMO silane 1.21% (0.56 kg.) and accelerant 0.18% (0.084 kg.).
9. Flooring and covering tiles and slabs wherein these items are made from a bonded mixture comprising 50 to 70% white quartz, 20 to 30% glass powder, 0.5 to 2% microspheres and 8 to 10% resin and additives.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
PCT/IT2007/000696 WO2009044417A1 (en) | 2007-10-03 | 2007-10-03 | Agglomerated material for floorings and coverings, as well as a method for obtaining the same |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
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PCT/IT2007/000696 WO2009044417A1 (en) | 2007-10-03 | 2007-10-03 | Agglomerated material for floorings and coverings, as well as a method for obtaining the same |
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WO2009044417A1 true WO2009044417A1 (en) | 2009-04-09 |
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PCT/IT2007/000696 WO2009044417A1 (en) | 2007-10-03 | 2007-10-03 | Agglomerated material for floorings and coverings, as well as a method for obtaining the same |
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Citations (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US6004663A (en) * | 1995-03-29 | 1999-12-21 | E. I. Du Pont De Nemours And Company | Solid surface material with foam backing |
WO2004043873A1 (en) * | 2002-11-13 | 2004-05-27 | The University Of Southern Queensland | Polymer concrete |
WO2005111126A1 (en) * | 2004-05-18 | 2005-11-24 | Luca Toncelli | Method for manufacturing a light article of conglomerate material and associated composite panel |
US20060270758A1 (en) * | 2003-07-11 | 2006-11-30 | Ong Ivan W | Composite material having the appearance of natural stone |
US7198833B1 (en) * | 2003-06-30 | 2007-04-03 | West Albert C | Artificial stone material and method of manufacture thereof |
-
2007
- 2007-10-03 WO PCT/IT2007/000696 patent/WO2009044417A1/en active Application Filing
Patent Citations (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US6004663A (en) * | 1995-03-29 | 1999-12-21 | E. I. Du Pont De Nemours And Company | Solid surface material with foam backing |
WO2004043873A1 (en) * | 2002-11-13 | 2004-05-27 | The University Of Southern Queensland | Polymer concrete |
US7198833B1 (en) * | 2003-06-30 | 2007-04-03 | West Albert C | Artificial stone material and method of manufacture thereof |
US20060270758A1 (en) * | 2003-07-11 | 2006-11-30 | Ong Ivan W | Composite material having the appearance of natural stone |
WO2005111126A1 (en) * | 2004-05-18 | 2005-11-24 | Luca Toncelli | Method for manufacturing a light article of conglomerate material and associated composite panel |
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