CH718180B1 - Interlocking stone element to be placed on the ground and marked at the same time with colour, method for manufacturing an interlocking stone element. - Google Patents

Abstract

A composite stone element designed to be placed on the ground and colored at the same time for better and longer lasting visibility. For this purpose, the interlocking stone element comprises a filler material component, a binder, a thermoset and a colorant component.

Description

The invention relates to a composite stone element for attachment to the ground and simultaneous color marking, which comprises a duroplast and filler component, and a method for producing such a composite stone element comprising a reaction resin and hardener component.

Known in the prior art interlocking stone elements are often used to occupy certain areas on the ground or to pave and to mark by applying dyes. The interlocking elements themselves do not show a high degree of coloration and/or wear out and accordingly are not easy to see, especially in the dark. For better visibility, color is often applied to the interlocking stone elements to identify markings on the floor. The markings are used to color-code areas on interlocking stone elements, to subdivide them, or to convey information. A missing color marking on interlocking stone elements, especially in the dark and/or poor weather and visibility conditions, can very easily lead to traffic accidents. It is therefore important that road users can see roads, lane boundaries, stop and dividing lines, bus bays, entrances, parking spaces, cycle paths, sidewalks, guidance systems and important traffic information by looking at the subsurface. However, the color on interlocking stone elements is subject to heavy wear and tear due to abrasion and weathering, which is why the interlocking stone elements are often not differentiated from the surroundings by a color contrast over a long period of time. By peeling off the paint, the color-contrasting interlocking stone elements underneath come to light. In a hot and dusty environment, paint markings also often tend to pick up particles on the surface. This soiling is often irreversible for thin layers of paint and is not removed again even by rain.

It is therefore an object of the invention to overcome these and other disadvantages of the prior art and to develop a composite stone element with colored markings, which have good visibility due to strong color contrast and maintain good visibility despite severe abrasion.

[0004] The object is achieved by a composite stone element and a method according to the independent claims.

A composite stone element for paving a floor and simultaneous color marking comprises a filling material component, in particular sand, and a binder. The binder comprises a duroplast, in particular an acrylate (co)polymer, and a dye component.

In this context, a composite stone element comprises a duroplastic material and filling material. The interlocking stone element is at least partially produced synthetically and includes components of organic chemistry. In particular, acrylate (co)polymers are particularly suitable, with compounds that include methyl methacrylate as a monomer being particularly suitable.

[0007] This interlocking stone element has the advantage that it is dyed through and can thus continue to have good visibility despite severe abrasion. It is no longer necessary to apply additional color to the surface of the interlocking stone element in order to apply markings to the floor surface. A large number of such interlocking stones are laid together to form lines or other shapes. Re-staining of the surface due to wear is no longer required. In the long term, the use of colored interlocking blocks according to the invention is therefore more economical than repeatedly marking the surface of a parking lot or similar.

[0008] This enables a flexible use of the interlocking stone element for color marking without further processing steps, such as the application of color, having to be carried out. Since no further processing steps are required, but the composite stone element already includes the additional colorant component, it is not necessary to ensure that a colorant adheres to the surface or can harden. This has the advantage of enormous time savings. In addition, no additional equipment, machines or tools are required for dyes and/or adhesives, often with multiple components, for application to the interlocking elements.

[0009] Furthermore, the application of color to interlocking stone elements is often difficult to implement if they have already been applied to the floor and have to be recolored. Certain areas/interlocking stone elements around the interlocking stone element may not be marked in color and have to be cut out, which is time-consuming.

Since the interlocking stone element already contains an additional dye component, it is also easy to form spatial structures for marking, such as walls, speed bumps and elevations, or paragraphs to sidewalks on which paint would run, or application or reapplication can only be carried out with a great deal of work could.

The dye component can be a liquid dye and/or a dye dispersion and/or color pigments.

The interlocking stone element can have a height extension, a width extension and a longitudinal extension, with none of the extensions being less than 1 cm, preferably 2 cm.

This has the advantage that the durability of the colored marking is ensured by the additional dye component in the composite stone element due to the minimum extension of 1 cm, preferably 2 cm, over a long period of time despite abrasion and the composite stone element has a high breaking strength.

Compared to the application of color to composite stone elements of the prior art, which have a significantly lower thickness of about 3-4 mm, a significantly more lasting color marking is thus possible. The application of dye components cannot have a thickness of more than 1 cm, in particular 2 cm, with comparable expenditure of time, since they would run or only have to be carried out in several layers in a laborious manner, which in turn would result in a great expenditure of time.

The composite stone element may comprise a reflective component, which preferably comprises siliconized glass beads. The reflective component is preferably applied to the surface of the interlocking stone element.

The composite stone element preferably comprises a reflective component such as titanium dioxide, siliconized glass beads, or coated high refractive index glass fume.

If the reflective component is included in the entire composite stone element or at least in a broader upper layer of the composite stone element, despite wear of the composite stone element surface, the reflective component remains visible. When the reflective component is applied to the surface of the composite stone, very effective visibility can be achieved with low material costs. A reflective component thus increases the visibility of the interlocking stone element, particularly in the dark and when visibility is poor.

The interlocking stone element can include the filling material, quartz sand, which in particular has a grain size in a range from 0.1 mm to 2 mm.

Since the composite stone element comprises sand as a filler component, the production cost is lower than when the composite stone element consists entirely of a binder. In addition, the filler material component, such as sand, ideally has greater hardness, increasing durability by reducing abrasion. In addition, sand as a filling material component means that the interlocking stone element has a roughness so that there is no risk of slipping. This reduces braking distances and minimizes the risk of slipping.

According to known forms of interlocking stones, the form of the interlocking stone element can also be produced in analogous forms. In principle, all possible forms are conceivable that can be cast and allow a floor to be evenly covered. For example, essentially polygonal, in particular hexagonal, octagonal, quadrangular base areas of the composite stone element are conceivable.

In this context, the interlocking stone elements can also have small bulges and/or projections, so that a minimum distance from one another is maintained and a joint is always formed. Round shapes, such as rounded corners, offer the advantage that they can be more easily detached from the interlocking element shape. The dimensions of the interlocking element should be in a similar range as known interlocking stones. For example, length L and width B can vary between 8 cm and 40 cm, so that the interlocking stone elements are still practicable in use.

The composite stone element can be used in combination with another material, so that the composite stone element forms only the uppermost layer of a composite stone made of the other material when installed. Since the interlocking stone element can only represent the top layer of an interlocking stone, material costs can be saved and the height can be adjusted to the expected abrasion. In addition, the interlocking stone element can be combined more cheaply with other interlocking stone elements of different sizes and is therefore more flexible in use.

A method for producing a composite stone element, in particular a composite stone element as described above, comprises the following steps: Mixing at least one reaction resin component with at least one hardener component, a filler component and an additional colorant component to form a mixture. The mixture or the individual components are filled into a composite stone element mold. The reaction resin component reacts with the hardener component, preferably by means of a radical (co)polymerization, so that a composite stone element is formed.

Such a manufacturing process enables the simple, inexpensive and fast production of long-lasting, arbitrarily colored interlocking stone elements in any form. The manufactured interlocking elements can therefore be easily added to existing interlocking stones.

The parameters such as temperature, humidity, mixing ratio and curing time can be checked and guaranteed more easily in the production facility for larger quantities, in contrast to production at each place of use individually. This also ensures consistent quality and the uniformity of the product. The reaction of the reaction resin component with the hardener component is very dependent on the temperature and humidity, and the right temperature can prevent inclusions of air bubbles and incomplete radical (co)polymerization. This also has the advantage that roads, parking lots, driveways or other floor coverings can be reused immediately after the composite stone element has been installed. There is no long waiting time for the curing and/or application of dyes at the point of use and therefore less working time.

Another advantage is that the interlocking elements can be reused for marking as opposed to applying paint. The interlocking stone elements can be easily removed as they do not stick by themselves and can therefore be used for a new purpose. In contrast to paints made from synthetic resins as markings, there is no permanent connection to the substrate.

This also has the advantage that incorrect attachment can be easily corrected and no unnecessary material is wasted.

In contrast to thin color markings, the original visibility can be easily restored, since the interlocking stone elements are colored throughout, the top layer of the surface, including the dirt, can be removed in order to restore the original visibility of the marking.

In addition, a sealing of the stones is easily possible, which is only possible with the use of normal color markings through multi-layer application and additional mounting. In this context, a second layer of reaction resin components and hardener components with other elastic properties, preferably harder, would be conceivable for the composite stone elements.

The method for producing a composite stone element can comprise an acrylate resin, the reaction resin component.

In this context, acrylate resins preferably include 2-component reactive resin formulations based on polyacrylates, copolymers and, in particular, polymethacrylates in a mixture of suitable ratios. The composite stone element includes acrylate resin as a reaction resin component, since the acrylate (co)polymers resulting from the manufacturing process are particularly break-resistant and have high elasticity. In addition, acrylate (co)polymers are often transparent, allowing greater visibility of the additional colorant component of the interlocking element. In addition, acrylate (co)polymers often have high temperature resistance, low abrasion and high oil resistance and are therefore particularly suitable for stable and low-wear composite stone elements. The interlocking stone element can also be produced by using acrylate resin using little organic solvents of only about 1 percent by weight. The method for producing a composite stone element can comprise a peroxide hardening component as the hardening component.

A reactive radical is required so that the radical chain reaction for the polymerization reaction can be initiated. This reactive radical is provided by the hardener component, preferably by a peroxide hardener component. Such a hardener component is very inexpensive since only a small amount of it is required because it only serves to make the first reactive radicals available and to trigger a chain reaction. As a result, little hardener component is consumed and there is little hardener component in the end product, the interlocking stone element. Nevertheless, too little peroxide hardener component must not be used, as termination reactions can take place and the reaction resin would therefore not react completely and would not be functional. By adding the hardener component, the radical (co)polymerization takes just a few minutes to hours, depending on the amount of material and the temperature. The interlocking stone element can thus be produced in a cost-effective and time-saving manner.

In the method, a weight mixing ratio of reaction resin component to hardener component of 100 to 0.1 to 1, preferably at least 0.5, particularly preferably essentially 0.5 can be used.

A complete reaction is achieved with such a mixing ratio.

The method may include a reflective component, preferably siliconized glass beads. The reflection agent component can be applied to the surface of the not yet hardened composite stone element during the mixing or preferably after the mixing of the other components.

Long-lasting visibility, in particular in traffic or in parking lots, is ensured by the fact that the mixture comprises reflective components.

In this context, it is conceivable to mix in the reflecting agent component so that visibility is still ensured even after progressive wear.

The application of reflective components on the surface of the not yet cured interlocking stone element with reflective components allows attachment only to the top layer and saves costs.

Alternatively or in addition to a reflective component, the mixture may comprise luminophores for marking the interlocking stone element. Luminophores are inherently luminous by exhibiting fluorescent or phosphorescent properties. The use of luminophores would have the advantage that the interlocking stone elements could also be perceived by vehicles or people if they did not have a light source.

The method may involve the paver mold into which the mixture is poured. The composite stone element mold is preferably made of metal and/or plastic and is preferably coated and/or treated with a release agent for better detachment of the hardened composite stone element.

The composite stone element form into which the mixture is poured must have a surface energy as low as possible so that the mixture adheres poorly to it. This is particularly important because the reaction resin component often forms a strong adhesive with a hardener component and would otherwise be difficult to remove from the composite stone element mold.

Appropriate coating or treatment with lubricant also ensures that no residues remain in the interlocking stone element form when loosening, which would adversely affect the functionality of the released interlocking stone element and potentially other interlocking stone elements in this interlocking stone element form.

The process can include the reaction resin component methyl methacrylate, 2-ethylhexyl acrylate and n-butyl acrylate, preferably in a mixing ratio of methyl methacrylate 1-50 wt%, 2-ethylhexyl acrylate 0.2-12.5 wt% and n-butyl acrylate 0.2-12.5 wt %, particularly preferably methyl methacrylate 5-10% by weight, 2-ethylhexyl acrylate 1-2.5% by weight and n-butyl acrylate 1-2.5% by weight.

The mobility of the polyacrylate chain of the acrylate (co)polymer affects how hard the polymer is. The mobility of the polyacrylate chain can be strongly influenced by the composition of the constituents of the monomers. The strength of the acrylate (co)polymer can be greatly influenced by additional methyl and ethyl groups and the length and shape of the acrylate compounds (methacrylate, hexyl acrylate and butyl acrylate). The longer the polyacrylate chain and the less chain mobility, the stronger the product. With this mixture of methyl methacrylate, 2-ethylhexyl acrylate and n-butyl acrylate, long chains can be formed without severe steric hindrance and, on the other hand, the mobility of the chains can be kept low. This mixing ratio thus enables a hard acrylate (co)polymer and, as a result, low wear and tear on the interlocking stone element.

In comparison to paints that are applied as a superficial color marking, the flexibility of the cured mixture does not have to be as great because there does not have to be a low-stress connection to the substrate. Due to the different expansion coefficients of reaction resin mixtures in relation to the substrate, solar radiation and wear and tear from traffic, reaction resin mixtures must be highly elastic in order to be able to adhere to the substrate over a long period of time. The composite stone element described does not have to do this because, unlike paint, it does not have to be applied and adhered. The mixture for the interlocking stone elements can thus be selected in such a way that, after hardening, it is harder and therefore more durable than surface color markings.

The method can have a processing temperature between 3°C and 45°C, in particular between 10°C and 25°C.

The processing temperature in a large interval enables flexible production at different times of the year without the need for additional heating or cooling of the production facilities.

In contrast to the application of paint to composite stone elements, the curing time of the composite stone elements is only important in production and not in use. Thus, even at very cold temperatures, at which the color would not harden, the interlocking stone element can be manufactured in the production facility and attached at the place of use.

The method can have an atmospheric humidity for processing the mixture below 90%, preferably below 75%. The temperature can be at least 3°C and in particular the components of the mixture can be warmed to room temperature before further processing.

By producing the interlocking stone element at below 90% or 75% relative humidity, it is ensured that the consistent quality and uniformity of the interlocking stone elements is guaranteed. Under certain circumstances, the reaction would take place very slowly or incompletely due to the entry of humidity, which would limit the usability of the interlocking stone elements.

The method can be characterized in that the mixture is filled into the composite stone element mold in such a way that the composite stone element has a height of at least 1 cm, preferably at least 2 cm.

This height provides longer wear resistance. In addition, it requires a composite stone element mold to harden such a mixture with a height of at least 1 cm, preferably at least 2 cm. For this reason, the same effect cannot be achieved, or can only be achieved by multiple applications of reaction resin dyes.

The height can be varied depending on the intended use and customer preferences for the various embodiments of known interlocking stone shapes. In this context, it is also conceivable to use the interlocking stone element in an interlocking stone that comprises a cheaper material. For example, a layered application of interlocking stone elements in the interlocking element form would be conceivable, which would generate an interlocking stone with high-contrast stripes, for example in different colors, for better visibility.

The method can include the filling material component quartz sand, which in particular has a grain size of 0.1 mm to 2 mm.

[0055] Quartz sand as a filling material component has the advantage that production costs are saved and the interlocking stone element has a high degree of roughness. This ensures greater safety for pedestrians and shorter braking distances for drivers.

Before the mixture of reaction resin component, hardener component, filler component and colorant component is poured into the mold, a composite stone layer, for example made of cement or concrete, can already be poured into the mold, so that the mixture is applied as a second layer to the composite stone layer and then is cured. The layer of the mixture here has a height of at least 1 cm, in particular 2 cm.

Such a two-layer interlocking stone element can be produced more cost-effectively.

[0058] The invention is explained in more detail with reference to figures, which merely represent exemplary embodiments. It shows: Figure 1: A composite stone element mold for a composite stone element, Figure 2: a top view of a composite stone element, Figure 3: an alternative composite stone element mold for a composite stone element, Figure 4: a top view of a composite stone element, Figure 5: another embodiment of a composite stone element mold, Figure 6: a top view of a composite stone element, FIG. 7: a further embodiment of a composite stone element form, FIG. 8: a top view of a composite stone element.

FIG. 1 shows a composite stone element mold for the production of a composite stone element according to the invention, into which the mixture of the reaction resin component and hardener component with filling material component and colorant is filled after mixing. The width of the mold is 130 mm, height 120 mm and length 140 mm. Before filling, the mold is treated with silicone spray so that the stone does not stick to it. A mixture comprising methyl methacrylate, 2-ethylhexyl acrylate and n-butyl acrylate is used as the reaction resin component. A peroxide hardener component comprising dibenzoyl peroxide and dicyclohexyl phthalate is used as the hardener component.

The composite stone element mold is pre-treated with a lubricant so that the mixture can adhere to it as little as possible. The interlocking stone element mold is made of PTFE (polytetrafluoroethylene), as PTFE has very low adhesion and thus adhesion is reduced. The mixture is poured into the mold a short time after the reaction resin component and hardener component have been mixed, since the radical (co)polymerization starts immediately.

The reaction resin component comprises a mixture of methyl methacrylate 5-10% by weight, 2-ethylhexyl acrylate 1-2.5% by weight and n-butyl acrylate 1-2.5% by weight. The hardener component includes a peroxide hardener component which includes dibenzoyl peroxide and dicyclohexyl phthalates.

The radical (co)polymerization has a pot life of 15-20 minutes at 20° C. and atmospheric humidity of 60%. As the chemical reaction takes place, the mixture heats up. While the reaction is not yet complete, siliconized glass beads are applied. After the reaction is complete and the interlocking stone element is finished, the interlocking stone element is easily released from the mold by the silicone spray. The interlocking stone element can now be used as a colored marking and for covering and paving. The interlocking stone element is now used as a color marking in a complementary uncolored interlocking stone so that it is well fixed and a color contrast is created.

[0063] FIG. 2 shows the base of a composite stone element after production in a composite stone element mold according to FIG. 1 in a plan view. The interlocking stone element has a length L and a width B in this embodiment. The corners are slightly rounded so that the interlocking stone elements can be placed next to each other more easily.

[0064] FIG. 3 shows an alternative form for the production of a composite stone element according to the invention. The filling and curing of the composite stone element takes place analogously to the description in FIG. 1. The width of the mold is 245 mm, height 100 mm and length 245 mm. However, in contrast to FIG. 1, the composite block element form has additional semi-circular bulges, 2 being arranged on each side of the base of the block, which can be seen in FIG. These bulges make it easier to arrange the interlocking stone elements on the floor, since regular joints are automatically created, since the bulges act as spacers. Thus, on the one hand, an even appearance and the drainage of water can be guaranteed. In this embodiment, one bulge is formed larger than all the others.

FIG. 4 shows the base of a composite stone element according to FIG. 3 in plan view. The length L and width B and the use are analogous to the description of FIG. The bulges also serve as teeth and counteract the slipping of the stone.

[0066] FIG. 5 shows a further embodiment of the composite stone element shape according to the invention. The filling and curing of the composite stone element takes place analogously to the description in FIG. 1. The width of the mold is 305 mm, height 80 mm and length 305 mm.

This embodiment has 6 smaller bulges per side arranged in pairs of three. Depending on the size of the bulges, the size of the joints between adjacent interlocking stone elements is also influenced.

FIG. 6 shows the base of a composite stone element according to FIG. 5 in plan view. The length L and width B and the use are analogous to the description of FIGS.

[0069] FIG. 7 shows a further embodiment of the interlocking stone element shape. The filling of the composite stone element mold and curing of the composite stone element according to the invention takes place analogously to the description in FIG. 1. The width of the mold is 295 mm, height 100 mm and length 295 mm. This embodiment has two bulges per side. A bulge is connected from two semi-circular bases and a straight bridge protruding from the side. The other bulge, on the other hand, has only the rounded, straight web and a semicircular bulge.

FIG. 8 shows the base of a composite stone element according to FIG. 7 in plan view. The length L and width B and the use are analogous to the description of FIGS.

Figure 9 shows the exemplary side view of the interlocking stone elements from Figures 2, 4, 6 and 8. The height of the interlocking stone H can also be seen, which is 11 cm for Figure 2, 9 cm for Figure 4, 7 cm for Figure 6 and 7 cm for Figure 8 is 9 cm.

Claims (14)

1. composite stone element for attachment to the ground and simultaneous color marking, comprising a filler component, in particular sand, and a binder, characterized in that the binder comprises a duroplastic, in particular an acrylate (co)polymer, and a dye component. 2. Composite stone element according to claim 1, characterized in that the composite stone element has a height dimension, a width dimension and a longitudinal dimension, wherein none of the dimensions is smaller than 1 cm, preferably none of the dimensions is smaller than 2 cm. 3. Composite stone element according to one of the preceding claims, characterized in that the composite stone element comprises a reflective component, preferably siliconized glass beads, wherein the reflective component is preferably applied to the surface of the composite stone element. 4. Composite stone element according to one of the preceding claims, characterized in that the filling material component comprises quartz sand, which in particular has a grain size in a range from 0.1 mm to 2 mm. 5. A method for producing a composite stone element according to one of claims 1 to 4, comprising the following steps: - Filling the individual components into a composite stone element mold and mixing at least one reaction resin component with at least one hardener component, a filler component and a colorant component to form a mixture or mixing at least one reaction resin component with at least one hardener component, a filler material component and a colorant component to form a mixture and filling the mixture into a composite stone element form, - Reaction of the reaction resin component with the hardener component, preferably by a radical (co)polymerization, so that a composite stone element is formed. 6. The method according to claim 5, characterized in that the reaction resin component comprises an acrylate resin. 7. The method according to any one of claims 5 or 6, characterized in that the hardener component comprises a peroxide hardener component. 8. The method according to any one of claims 5 to 7, characterized in that a weight mixing ratio of reaction resin component to hardener component of 100 to 0.1 to 1, preferably at least 100 to 0.5 is used. 9. The method according to any one of claims 5 to 8, characterized in that a reflection agent component, preferably siliconized glass beads, is applied to the surface of the not yet hardened composite stone element during the mixing or preferably after the mixing of the other components. 10. The method according to any one of claims 5 to 9, characterized in that the composite stone element mold into which the mixture is poured consists of metal and/or plastic and is preferably coated and/or treated with a release agent for better detachment of the hardened composite stone element. 11. The method as claimed in any of claims 5 to 10, characterized in that the processing temperature is between 3°C and 45°C, in particular between 10°C and 25°C. 12. The method according to any one of claims 5 to 11, characterized in that the humidity for processing the mixture is below 90%, preferably below 75%, and the processing temperature is at least 3°C and in particular the components of the mixture are at room temperature before further processing have been heated. 13. The method according to any one of claims 5 to 12, characterized in that the mixture is filled into the composite stone element mold in such a way that the composite stone element has a height of at least 1 cm, preferably at least 2 cm. 14. The method according to any one of claims 5 to 13, characterized in that the filling material component comprises quartz sand, which in particular has a grain size of 0.1 mm to 2 mm.