BR112013021356B1 - mixture for the manufacture of a rock laminate and article prepared by forming the mixture - Google Patents

Abstract

MIX, STONE BLADE AND PLATE BASED ON VOLCANIC ROCK PARTICLES, USEFUL IN CONSTRUCTION AND DECORATION; AND PROCESS FOR THEIR PRODUCTION The present invention describes a mixture to produce a stone veneer on a solid base, useful for decoration. The mixture includes an adhesive composition of a binding agent comprising particles of volcanic rock that have particle sizes of 1 to 5 microns and a mixture of polymers in a sufficiently combined portion to act as an adhesive to the other components of the laminate; a silicate compound in a proportion sufficient to stabilize the composition; and water in the proportion necessary to moisten and fluidize the composition. The mixture may contain other components for the production of laminates or forms and may be formed in the form of a plate or on a plate useful for the construction and decoration of buildings, consisting of a rock blade made from the above mixture and a base solid. Methods for preparing the aforementioned mixtures and plates useful for the construction and decoration of construction surfaces are also disclosed.

Description

MIXTURE FOR THE MANUFACTURE OF A ROCK LAMINATE AND ARTICLE PREPARED BY THE FORMATION OF THE MIXTURE TECHNICAL FIELD OF THE INVENTION

[001] The present invention refers to a technical field of construction, decoration, specifically in the finishing and decoration of buildings, since it proposes a mixture of stone sheet and plate, useful for the finishing and decoration of building surfaces and other objects, as well as the methods for their production. These products are made from volcanic rock particles.

BACKGROUND OF THE INVENTION

[002] Volcanic rocks have always been a material highly valued for their great beauty and the fact that they could be easily cut and sculpted by man. This contributed to making them scarce and its use in modern buildings made it more expensive, which is why it was converted into an elitist product that can only be used in luxury buildings. These rocks are also known as igneous rocks or clastic igneous rocks; the rock that is composed, for example, of fragmented volcanic products that were expelled by volcanoes during explosions.

[003] The soil erosion in Mexico due in part to the exploitation of volcanic rocks in the quarries was 718 million tons, resulting in an environmental contamination of more than 37 million tons of unusable solid waste in the national territory (INEGI, system of accounts 2004).

[004] Several plates are known to have an appearance that imitates natural stone, but they are nonetheless imitations, since when they are touched, when they are smelled and when they are observed up close, it is perceived perfectly not stones. These boards are generally used in buildings made largely of prefabricated building materials in order to save installation costs and time to be invested.

[005] In this category there are also plates made of aluminum, polyethylene and other materials or a coating with natural stone that was extracted in limited dimensions in relation to its weight and the size of the plate that serves as the base. These stones, in turn, are adhered to the plates by means of synthetic adhesives, so that the production process of these plates has very high costs and dimensions limited to the size of the rock from which they are extracted, making the piece and manufacturing method have limited its size and shape.

[006] Natural volcanic rock slabs have been around for thousands of years and their biggest drawbacks are their weight, the difficulty of transporting them and their placement. The plates extracted from natural volcanic rocks usually have a certain fragility when they are maneuvered, as vibrations or impacts on them, can cause their fragmentation. For this reason they must be made having a sufficient thickness to have a greater strength and resistance to fragmentation. When installing on a wall, these boards usually have colossal weights that make it difficult or, as in some cases, prevent their installation without them or the walls being damaged. The wall on which they are installed must be of a resistant material and sufficiently firm so that it can support the weight of the board. Even so, there is always the risk of constant impacts that occur at the time of fixation and that can fracture the plate.

[007] Due to the aforementioned drawbacks, stone plates useful in construction and decoration that are based on volcanic rock particles are necessary, as well as their formulations and production processes that are proposed by means of the present invention.

OBJECT OF THE INVENTION

[008] The invention refers to various adhesive compositions and mixtures for the manufacture of products that will be used in the state they are in or in the construction of buildings.

[009] An object of the present invention relates to an adhesive composition for the manufacture of a laminate that molds from a binding agent composed of volcanic rock particles that have a particle size of 1 to 5 microns and a mixture of polymers in a combined amount sufficient to act as a binder for other components of the laminate; a compound of silicates in a proportion sufficient to stabilize the composition and a sufficient proportion of water to moisten and fluidize the composition.

[0010] In this adhesive composition, volcanic rock particles are present in a proportion of 25 to 50%; the mixture of polymers is present in a proportion of 10 to 40%; and the silicate is present in a proportion of 1 to 10%, all percentages based on the weight of the dry composition. Water is added to allow the dough to be combined with other materials to form a mixture for making the laminate. The mixture consists of the adhesive composition and a charge of solid particles of rock, plastic, glass, wood, metal or mineral material.

[0011] Another objective of the invention relates to a preferred mixture for the manufacture of the laminate which is composed of volcanic rock particles that have diameters between 1 micron and 3 mm, present in a proportion greater than 50% of the mixture; a binding agent composed of a mixture of polymers in a proportion sufficient to act as a binder for the rock particles; a silicate compound in a proportion sufficient to stabilize the mixture; and a sufficient proportion of water to moisten and fluidize the composition.

[0012] The rock particles are advantageously present in a proportion of approximately 58% to 88% of the mixture, with the rock particles present in a wide variety of different size fractions, including a first fraction, which is particle size from 1 to 5 microns, present in a proportion of 18 to 28% by weight of the mixture; a second fraction having a particle size of 0.25 mm to 1.75 mm, present in a proportion of 10 to 20% by weight of the mixture; and a third fraction having a particle size of 2 mm to 5 mm, present in a proportion of 30 to 40% by weight of the mixture.

[0013] The binding agent is preferably emulsified and is present in a proportion of 8 to 25% by weight of the mixture. This agent is composed of a block copolymer redispersible in water and a vinyl polymer with a weight ratio of 1: 4 to 3: 2, preferably 1: 1 to 2: 3. The water redispersible polymer powder is composed of a block copolymer in the proportion of 4 to 10% by weight of the mixture, and the vinyl polymer in the proportion of 4 to 15% by weight of the mixture.

[0014] A preferred block copolymer is a copolymer of butyl acrylate and styrene, whereas the vinyl copolymer is composed of a combination of the vinyl acrylic copolymer present in an approximate proportion of 3 to 10% by weight of the mixture, and a poly (vinyl acetate) resin present in the proportion of approximately 1 to 5% by weight of the mixture.

[0015] The mixture also includes a silicate compound to improve the stability of the mixture. This compound is preferably a magnesium hydrosilicate in a proportion of approximately 1 to 5% by weight of the mixture. The silicate compound can also be kaolin clay, such as, for example, Al2Si2O5 (OH) 4

[0016] The mixture includes water in a proportion of approximately 15 to 30% by weight to facilitate processing and combining the ingredients.

[0017] Another object of the invention refers to an article prepared by molding one of these mixtures to give it the desired shape and allowing the formed mixture to dry. The shape can include a blade, a plate, a tile, a column or a beam that has a polished outer surface to achieve the desired finish. The polishing finish can also be treated with a sealer. The article can include metal, glass, wood, or fiber reinforcements or it can be provided on a plastic substrate, metal wood, some inorganic mineral, cement or concrete, the substrate optionally containing an adhesive to fix the article to the floor or to a building. The article can be manufactured as an interior or exterior structural component of some building or other structure.

[0018] Another object of the invention relates to a method for preparing mixtures by providing water in a proportion between 0.1 and 0.4 liters for each kilogram of volcanic rock particles and for homogenizing the mixture. The binding agent is preferably emulsified and the mixture is homogenized in a conventional mixer operated at a speed of 500 to 1000 rpm for a period of 30 to 120 minutes.

[0019] The homogenized mixture can be used to form a good number of different articles. Another object of the invention is a method of forming a decorative stone article, molding the homogenized mixture into a desired shape and allowing the formed mixture to dry. The homogenized mixture can be shaped into a desired shape by gluing or molding. Generally, the homogenized and dried mixture is ground and polished to obtain the desired finish and, optionally, some sealer is applied later. The method also includes the formation of the homogenized mixtures on some substrate; grind and polish the mixture to obtain the desired finish and optionally provide the substrate with some adhesive to fix the article to the floor, a wall or the side walls of some structure. The material can also be used to form these parts of the structure.

BRIEF DESCRIPTION OF THE FIGURES

[0020] The characteristic details of the mixture, the stone blade and plate, the base of volcanic rock particles, useful in the construction, decoration and the production process, of the present invention, are clearly shown in the description that follows and in the tables and accompanying figures.
Figure 1 is a graph showing the plate weights of the present invention compared to commercial products.
Figure 2 illustrates the behavior of the thermal conductivity of the plate in question and of some commercial products.
Figure 3 shows the resistance of the plate of the present invention and some commercial products to hydrochloric acid.
Figure 4 illustrates the installation time for the card in question and other commercial products.

DETAILED DESCRIPTION OF THE INVENTION

[0021] The present invention proposes products that take advantage of the beauty and the high perceived value of volcanic rocks such as, for example, igneous rocks or clastic igneous rocks and that originate from the residues generated by the exploitation of the deposits of these rocks that exist limited places in the world. When these deposits are explored, a large proportion of waste is generated that produces a great deal of environmental contamination due to the fact that the volcanic rocks that are removed from these deposits are not used in 100%.

[0022] The present invention now recycles this volcanic rock waste to create new and useful rock panel products. These products take advantage of the waste generated when large blocks of volcanic rock are extracted, to create volcanic rock slabs manufactured with the same characteristics as natural volcanic rock slabs and to convert this waste into volcanic rock slabs that replace 100% of the slabs of natural volcanic rock, however, having the advantage of not producing any contamination and being the lightest plates, in addition to the additional attributes described in this document.

[0023] The plates created by the invention have a good number of desirable characteristics. They have the same appearance, texture, color and aroma as natural volcanic rock stones or dimensional rocks, but are at least 50% lighter than natural volcanic rock plates. In addition, they are more resistant to acid rain (hydrochloric acid, sulfuric acid and nitric acid) due to the use of volcanic rocks that have this property. They are resistant to ultraviolet rays, never change their color and require minimal maintenance, and can be used to protect themselves from these rays when desired. The plates are installed in a functional, easy and quick way on any prefabricated or traditional element.

[0024] The invention relates to a mixture for the elaboration of a stone sheet on a solid base that can be used for construction and decoration, preferably formed by particles of volcanic rock; an acrylic vinyl copolymer; a poly (vinyl acetate) resin; copolymers of butyl acrylate and styrene; magnesium hydrosilicate; and water.

[0025] The invention also relates to a stone blade for decorating surfaces, obtained with the aforementioned mixture. Another manifestation of the invention relates to a plate useful in the construction and decoration of buildings, which comprises a stone blade already mentioned and a solid base.

[0026] In addition, some specific methods for preparing the aforementioned mixture include: i) mixing the distinct particles that make up the volcanic rock particle portion in a conventional manner; ii) moisten the portion of volcanic rock particles with 1 L of water for every 4 kilograms of volcanic rock particles; iii) add, in its entirety, the vinyl acrylic copolymer; poly (vinyl acetate) resin; butyl acrylate and styrene copolymers; and magnesium hydrosilicate; and iv) making a homogenized mixture with a conventional stainless steel stirrer at a speed of 500 to 1000 rpm, for a period of 30 to 120 minutes.

[0027] The present invention also includes specific methods for the production of the aforementioned slab and include: i) delimiting, on the solid base, the area where the stone blade is placed, with a peripheral edge on the solid base for this object ; ii) uniformly add the mixture described in steps 1, 2, 3 and 4 over the area defined in the previous step until it covers the peripheral border; iii) allow the mixture to air dry for 24 to 72 hours; iv) rough the plate with diamond cups, depending on the type of finish, rustic or smooth; v) cleaning the laminated plate of the residues, preferably originated by aspiration; vi) apply a layer of water-tight sealer on the slide; and vii) let the water-tight sealer air dry for 3 hours. For faster pick-up, heat or other forms of energy, such as, for example, microwaves, can be used to dry the material.

EXAMPLES

[0028] The examples below show how to formulate the binder compositions and mixtures of the invention for the preparation of various articles.

[0029] The invention was started with volcanic rock particles obtained from waste and tests were carried out to find the best combination of the volcanic particles with the binding agents. Binders are generally copolymers sold commercially in emulsion and powder form, as well as resins. Water was also used to moisten the particles and to complete the volume of the mixture, in a proportion of 1 liter of water for every 4 kilograms of particles. Table 1 shows the results.

[0030] As can be seen in Table 1, these tests demonstrated that the best combination of binding agents was the combination of butyl acrylate and styrene + poly resin (vinyl acetate) + vinyl vinyl copolymer, due to the fact of presenting greater plasticity, shorter drying time and no visible cracks. The shortest acceptable drying time was 72 hours, as no binding agent has a drying time of less than 72 hours.
Table 1. Behavior of different binders mixed with volcanic rock particles

[0031] Plasticity was measured on a scale of 0 to 10, where the highest value indicates high plasticity.

[0032] Once the best combination of binding agents was found, an investigation was made into the best proportions or concentrations of each of the components. An experiment was carried out in which we submitted each of the components to different amounts until finding the optimal proportions. These results can be seen in Table 2.

[0033] To give this mixture greater water resistance, additional components have been added, especially alkaline hydrosilicates, such as magnesium hydrosilicate or kaolin clay, thus obtaining the creation of a colloid mixture that is similar to volcanic lava, but at room temperature, which has the property of adhering to any material, and which when drying has the same physical characteristics as a natural volcanic rock, and for this reason the same finishes as are given to stone plates natural dimensions.

[0034] When analyzing the different proportions of the components of the mixture in question, we observed that, when we used 10 to 40% of all copolymers in combination with silicate and water, there was a considerable number of particles that broke off per square centimeter ; the best ranges being 1 to 10%, except in water, where the corresponding range was 1 to 20%.

PD = partículas desprendidas. A aparência foi qualificada com base em uma escala de 1 a 5, em que o valor mais alto significa uma aparência melhor. E a dureza foi qualificada em uma escala de 1 a 10.[0035] When the copolymers and magnesium hydrosilicate were applied in a proportion above 40%, the appearance of the slide was not desirable, since the excess causes the relief of the volcanic particles to be lost. It was decided not to use these proportions for decorative purposes, despite the resulting slabs having a good hardness. These boards can be used in other applications, such as when abrasion or wear resistance is desired, without the need for a decorative appearance.
Table 2 - Behavior of the different proportions to which the components of the adhesive mixtures obtained were subjected

PD = detached particles. The appearance was qualified based on a scale of 1 to 5, where the higher value means a better appearance. And the hardness was rated on a scale of 1 to 10.

[0036] We found that copolymers can be mixed with water (see Table 3) and that the fine powder of the pulverized volcanic rock contains inorganic binders (inorganic functional minerals) which when mixed with water and with acrylate-based copolymers butyl and styrene undergo a modification that allows them to have greater cohesion, adhesion and flexibility. With this combination we were able to laminate the base plates with natural volcanic rock, but when they were dried, cracks were created in the laminates and we found that this laminate had a low resistance to friction and water. For this reason, a resin in poly (vinyl acetate) emulsion, when added with the vinyl-acrylic emulsion copolymer, improves the stability of the mixture, thus improving its adhesion, its resistance to friction and water. In addition, the resulting plates showed no cracks.
Table 3. Percentage of inorganic binders from different volcanic rock particles

[0037] As can be seen in Table 3, the best combination of volcanic rock particles for the production of the mixture for the manufacture of the laminate or for other products was 1 micron to 3 mm; 3 mm + 1 mm + 3 microns. The combination of 2 mm + 1 mm + 2 microns as well as the combination of 1 mm + 5 microns + 1 micron; and at 5 microns + 0.25 mm at 1.75 mm + 2 mm at 5 mm also showed excellent results, so that these combinations are also considered in the present invention. However, for any specific formulation, adherence capacity and appearance are taken into account to determine the optimal mixture. Generally, better adherence is obtained with the use of smaller particles, while appearance is judged based on the absence of cracks or fissures (through the evaporation of gases within the mixture during setting) and the resulting similarity with rock not processed. Care must be taken as particles that are too small produce cracks, while larger grain sizes give the finished product its natural appearance.

[0038] Having created the preferred mixtures mentioned in this document, we proceed to laminate this mixture on a solid base and after several attempts we arrive at the following optimal method; i) delimit on the solid base, the area where the stone sheet is placed for which a peripheral edge is provided on the solid base; ii) uniformly add the mixture described in steps 1, 2, 3 and 4 over the area defined in the previous step until it covers the peripheral border; iii) let the mixture air dry for a period of 24 to 72 hours; iv) rough the plate with diamond cups, depending on the type of finish: rustic or smooth; v) cleaning the laminated plate of the residues, preferably originated by aspiration; vi) apply a layer of water-tight sealer on the slide; and vii) let the waterproof sealer air dry for 3 hours. The peripheral edge can be a rigid strip or strip, the height of which depends on the thickness you want the stone blade to have.

• i) Misturar as partículas distintas que constituem a porção de partículas de rocha vulcânica de modo convencional;
• ii) Umedecer a porção de partículas de rocha vulcânica com 1 litro de água para cada 4 quilogramas de partículas de rocha vulcânica;
• iii) Agregar, na sua totalidade, o copolímero vinil acrílico; a resina de poli(acetato de vinila); os copolímeros de acrilato de butila e estireno; e o hidrossilicato de magnésio; e
• iv) Homogeneizar com um agitador de aço inoxidável convencional, de preferência, a uma velocidade de 500 a 1000 rpm, durante um período de 30 a 120 minutos.

[0039] The way of preparing the mixture to produce a stone sheet with the appearance of volcanic rock, comprises the following steps:

• i) Mix the distinct particles that make up the volcanic rock particle portion in a conventional manner;
• ii) Moisten the portion of volcanic rock particles with 1 liter of water for every 4 kilograms of volcanic rock particles;
• iii) Add, in its entirety, the vinyl acrylic copolymer; poly (vinyl acetate) resin; butyl acrylate and styrene copolymers; and magnesium hydrosilicate; and
• iv) Homogenize with a conventional stainless steel stirrer, preferably at a speed of 500 to 1000 rpm, for a period of 30 to 120 minutes.

[0040] Qualified technicians are aware that these optimum conditions may vary as needed, depending on the specific formulation and the final article that will be prepared. The homogenization speed and time, for example, may vary depending on the final components of the mixture, and these components may be added in parts or all at the same time, depending on the size of the product produced. It is preferable to emulsify the binding agent before mixing it with the other components. In addition, the drying or resting time of the mixture to solidify until reaching the final hardness condition, may vary depending on the amount of water added in relation to the concentrations of the other components.

[0041] The mixture obtained is somewhat similar to cold volcanic lava that has the property of adhering to any material. When it dries, it has the same hardness and physical characteristics as a natural volcanic rock, which is why it can be given the same finishes. It is important to note that 90% of the formula comes from natural products.

[0042] For this reason, the invention also comprises a plate useful in the decoration of building surfaces as well as other objects, this plate comprising the stone blade originating from the mixture already described.

[0043] The plates resulting from the process that is disclosed in this patent application are, preferably, the solution for the use of natural stone in modern architectural projects that, due to their dimensions, weight and structures, could never be coated with traditional plates of natural volcanic rock, as it has weight restrictions and an installation at a certain altitude.

[0044] The intrinsic characteristics of this plate make it a product that has many applications in the construction and decoration industry. This board has all the advantages of natural dimensional stones (it never changes heat, it has the appearance, aroma and texture of natural rock), however without the disadvantage of weight, since it is a much lighter product (even 7 0% less weight) and can be used as a facade for buildings, shopping centers, schools, hospitals and houses. As a decorative element for interior and exterior walls, as well as ceiling tiles for ceilings. It can be used for an unlimited number of purposes, being limited only by imagination. The mixture used for the laminate of the plates allows us to apply the colloid mixture without the need to use a mesh for its adhesion when drying, the rock adheres to the material of the used plate creating a unique cohesion. The roughing with diamond cups gives it an appearance similar to that of dimensional ornamental stones that are cut and polished with diamond discs.

[0045] The variety of laminates on the slabs that can be obtained is equal to the variety of types and colors of natural stones found in different deposits of volcanic rocks worldwide.

[0046] The qualities of this plate are shown below, and together with the attached figures, the results that are not obtained by any of the conventional products can be verified. More specifically, the weight of the plate is 70% less than that of natural volcanic rock. Its appearance, texture, color and aroma are the same as those of natural stone. The intended plates have flexibility, as well as the ability to provide thermal insulation, resistance to acids, resistance to high temperatures, resistance to water and the action of bacteria, fungi and other organisms related to humidity, and resistance to ultraviolet rays (their color never changes). Plates are also useful for providing sound insulation and require quick and easy installation on any heavy or light material.

[0047] These laminated sheets of volcanic rock can be used as a facade for buildings, shopping centers, schools, hospitals and houses. As decorative elements they can be used for interior and exterior walls as plafoniês for ceilings. They can be used for an unlimited number of purposes, their only limit being imagination. One of its great advantages is the ease of installation, as they can be installed indoors and outdoors with the same ease using the same conventional frames and screws that are used to install plasterboard. For exteriors they are installed with the same ease as the cement slabs and the same conventional frames and screws as the cement slabs are used. In the case of plafoniés, they are installed with the same ease as plafoniés using the same conventional systems for their placement.

[0048] These boards have the advantage of being fixed directly to the walls with screws, adhesives or mortar without the need to use frames. They can also be used to manufacture furniture and decorative items, such as tables and furniture tops or countertops.

[0049] It is important to highlight that the mixture in question can be applied on surfaces of solid objects to decorate them, such as containers, bottles, cans and any solid surface. For this purpose, the surface of the object is simply cleaned, the mixture is applied by direct contact and is allowed to dry, then thinning. After the dust has been removed, the water-tight sealer is added and the object is finished with its stone laminate.

[0050] The final products produced, preferably, for the construction field, are capable of being used as weight support or as structural elements in construction. The mixture can be reinforced, as needed, for these applications.

[0051] It is also possible to use the adhesive compositions provided for in the present invention with some load of other solid particle materials other than rock, and even then it will be possible to prepare articles and laminates. Suitable loading materials include plastic, wood, glass, metals or minerals. These loading materials can be of any size selected to provide the article or laminate with a certain appearance or aesthetic or functional structure.

[0052] The adhesive mixture is formed from components that can be combined to connect the load so that a solid and dense product is formed, which, in turn, can be shaped to form the desired article as an alternative to laminates stones described in this document. More specifically, the adhesive mixture uses a combination of volcanic rock particles that have a relatively small particle size of 1 to 5 microns, and a mixture of polymers that work together in the combined amount to act as an adhesive for the other components of the laminate. The amounts of these components are determined on the basis of a dry bond composition, and the volcanic rock particles are present in a proportion of 25 to 50%, whereas the polymer mixture is present in a proportion of 10 to 40% . Any of the polymer mixtures described in this document for use in the mixtures can be used in the adhesive composition. Another component of the adhesive mixture is the silicate of the types that are described herein and are used in the proportion of 1 to 10% to stabilize the adhesive mixture. The components are all mixed with water in a proportion sufficient to moisten and fluidize the composition. The adhesive mixture is then combined as the filler. Generally approximately 40 to 60% by weight of the adhesive combines with 40 to 60% by weight of the filler to form a mixture that can be used to form a laminate or other article, in the same way as the rock mixtures of the invention are used. .

[0053] The resulting products may vary depending on the user's desire and can be used in a good number of different ways. The mixture itself can be spread over the floor of a structure, then left to dry before polishing or sealing to obtain the texture or the final finish. Tiles or panels can be produced by applying the mixtures to any suitable substrate, including any wood, plastic, metal, aluminum, cement, ceramics or other support materials that allow the dry part to be moved or transported to the desired location. The back of the support may include some adhesive to fix the tile to the floor, wall or furniture. When relatively thin panels are used, they can be attached to the structure using screws and nuts. The panels can be provided with openings or holes in the panels to receive nuts or other assembly tools. It is also possible to fix the tiles or panels to steel structures that are used for the construction of buildings, providing the panels or tiles with a decorative covering for the buildings.

[0054] The mixture can also be shaped through molding or gluing to obtain the desired configuration. In this way, a variety of blocks, cubes, rods and other shapes can be prepared. The exposed surface of the article can be polished, depending on the texture and finishing desired end. A conventional concrete or ceramic sealer can be applied after obtaining the final product. When molding the mixture to form a product, several reinforcement materials can be used, including fiberglass, steel bars or plates, or a load of wood, glass, ceramic or other stone may be included, depending on the requirements desired appearance and strength.

[0055] They can easily manufacture specific construction products, including walls, blocks or wall elements, fountains, pipes, window or door frames and other structural elements for weight or decorative support due to the versatility and ease of application of the mixture. These products are resistant to moisture, acids or acid rain, sea water and other environments, as they retain their beauty for years due to their natural durability.

Claims (6)

Mixture for the manufacture of a rock laminate, characterized by the fact that it comprises:
volcanic rock particles having diameters between 1 μm and 5 mm present in an amount above 50% by weight of the mixture, where the rock particles are present in at least three fractions including a first fraction having a particle size of 1 to 5 microns and being present in an amount of 18 to 28% by weight of the mixture; a second fraction having a particle size of 0.25 mm to 1.75 mm and being present in an amount of 10 to 20% by weight of the mixture; and a third fraction having a particle size of 2 mm to 5 mm and being present in an amount of 30 to 40% by weight of the mixture;
the rock particles are present in an amount of 58% to 88% by weight of the mixture;
an emulsified binding agent is present in an amount of 8 to 25% by weight of the mixture and comprises a water-dispersible block copolymer and a vinyl polymer in a weight ratio of 1: 4 to 3: 2;
a silicate compound is a magnesium hydrosilicate and is present in an amount of 1 to 5% by weight of the mixture;
water is present in a proportion of 15 to 30% by weight of the mixture. Mixture according to claim 1, characterized in that the water-dispersible polymer powder comprises the block copolymer in an amount of 4 to 10% by weight of the mixture; and the vinyl polymer in an amount of 4 to 15% by weight of the mixture. Mixture, according to claim 1, characterized by the fact that it comprises:
volcanic rock particles having diameters between 1 μm and 5 mm present in an amount above 50% of the mixture;
a binding agent comprising a polymeric mixture in an amount as a binder for rock particles, with the mixture comprising a water-dispersible block copolymer and a vinyl polymer in a weight ratio of 1: 4 to 3: 2, wherein the block copolymer is a copolymer of butyl acrylate and styrene, and the vinyl polymer comprises a vinyl acrylic copolymer present in an amount of 3 to 10% by weight of the mixture; and a poly (vinyl acetate) resin present in an amount of 1 to 5% by weight of the mixture;
a silicate compound in an amount to be mixed; and
water in an amount to moisten and fluidize the mixture. Article, characterized by the fact that it is prepared by forming the mixture, as defined in claim 1, in a desired format and allowing the formed mixture to dry. Article according to claim 4, characterized by the fact that it is in the form of a sheet, plate, tile, column or beam having an outer surface that is polished to the desired finish. Article according to claim 4, characterized by the fact that it includes metal, glass, wood or fiber reinforcement or that it is supported by a plastic, wood or metal substrate, with the substrate optionally containing an adhesive to fix the article to a floor or building.

Images