CN110520396A - 用于用硬化粘合剂来制造呈板或块的形式的物品的方法以及由此获得的物品 - Google Patents
用于用硬化粘合剂来制造呈板或块的形式的物品的方法以及由此获得的物品 Download PDFInfo
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- B29C67/00—Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00
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Abstract
在用于制造通过一定程序获得的呈板或块的形式的物品的方法中,在所述程序期间,包含骨料和粘合剂的初始混合物经历真空振动压缩,随后是包括粘合剂的硬化的步骤,骨料包括具有大于或等于5莫氏硬度的硬度的合成骨料和填料,所述合成骨料和填料包含大体上仅呈无定形形式的二氧化硅。
Description
本发明涉及用于用硬化粘合剂来制造呈板(slab)或块(block)的形式的物品的方法以及由此获得的物品。
具体地,本发明涉及用于制造呈板形式或块形式的物品的方法,其中初始混合物(initial mix)由具有预先确定的粒度的石材或石材样材料的颗粒物以及有机硬化粘合剂和/或无机硬化粘合剂组成。
已知例如使用体系来制造这种类型的板,在体系中,由石材材料骨料和粘合剂组成的混合物被倾倒入临时保持器中并且在真空下在同时压缩的情况下经受振动(真空振动压缩(vacuum vibro-compression))。
此工艺的重要部分是真空振动压缩,真空振动压缩允许使用最少量的粘合剂的可能性,并且因此允许使用最大量的石材或石材样骨料的可能性,这获得具有非常天然外观的板。
利用此工艺,可以获得具有也与2.1m×3.6m一样大的尺寸以及可以与30mm或更多一样厚的厚度的板。
考虑到初始混合物的可能成分,这些成分可以包括骨料、填料、粘合剂、添加剂以及着色剂。
骨料通常由天然矿物组成,这些矿物可以具有硅质性质,例如石英、花岗岩、斑岩、玄武岩、石英岩、硅砂;或者具有钙质性质,例如大理石、白云石、有色石材(colouredstone)等。
取决于在最终产品中要获得的美学特性和物理特性/机械特性,这些材料可以以不同尺寸的砂或颗粒物的形式使用。
有时,出于美学的原因,制剂还可以包括有色玻璃颗粒物(coloured-glassgranule),即使它们不是非常耐刮擦的,具有通常不大于4的莫氏硬度;或其他装饰性要素(element),例如压碎的壳(crushed shell)。有时,玻璃颗粒物还以高百分比使用,以便获得特殊的美学效果,即使获得具有差的耐刮擦性或耐磨性的物品。
矿物填料是与粘合剂一起使用以形成所谓的粘合糊剂(binding paste)的材料。填料通常由精细碾磨的多种类型的石材材料组成,例如用于用硅质骨料形成的团聚物(agglomerate)的充气二氧化硅(aerated silica)或充气长石(aerated feldspar)以及用于用钙质骨料形成的团聚物的碳酸钙或氢氧化铝。
使用分别碾磨成砂或细粉末的石英作为骨料或填料制成的物品在商业上已经变得广泛。由于石英的透明性,在合适地添加有色颜料的情况下,可以生产具有高品质外观(high-quality appearance)的物品,这些物品非常耐刮擦/磨损和耐化学剂例如常用的酸(柠檬汁中包含的柠檬酸、作为醋的组分的乙酸等)。
常用的有机性质的粘合剂是树脂,例如不饱和聚酯树脂,或丙烯酸树脂或丙烯酸/聚氨酯树脂,或另外植物来源的树脂,例如用酸酐环氧化的籽油。
可选择地,可以使用胶结性质的粘合剂。
如本领域技术人员熟知的,在树脂的情况下,硬化优选地通过在烘箱内部施加热来进行,而在胶结粘合剂的情况下,需要进行板的固化。
添加剂是以小量添加至混合物中以便获得给定结果的组分,例如用于使树脂或有色颜料硬化的催化剂和促进剂(accelerator)。
这种类型的方法被描述在意大利专利第1117346号和第1056388号中。
现有技术尽管被广泛地使用和理解,但其并非没有缺点。
一个特别麻烦的缺点起因于使用诸如石英或石英岩或硅砂的材料作为骨料和填料,或者更通常地,使用在最终产品的机械加工(例如板的切割)期间导致形成呈结晶态的二氧化硅(SiO2)粉尘的材料。
此粉尘当分散到大气中时,如果被吸入,可能对人体健康非常有害,造成被称为硅肺病的肺病。
该问题对于本领域技术人员是熟知的,并且通常进行机械加工的人员应当穿戴被设计成防止吸入粉尘的个人防护装置。
然而,如果在机械加工例如切割或成形期间,水被输送到工具和材料之间的接触的区域中,则该不出现问题,因为这防止呈粉尘的形式的有害物质传播到空气中。
然而,这两种预防条件(使用个人防护装置和/或用水喷雾机械加工区)并不总是被遵守,并且因此存在对在上游产生最终产品的需求,所述最终产品具有期望的机械性质和/或色彩性质,但完全避免对操作者有害的物质的产生并且从而避免可能导致对操作者的健康严重损伤的不正确的行为的后果。
本发明的目的是结合石英作为骨料和填料的广泛工业使用,至少部分地解决现有技术的缺点。
因此,本发明的第一任务是提供用于制造物品的方法,所述物品在不使用石英的情况下制成,但是在外观和性能方面具有类似于包含石英并且在机械加工操作期间不产生结晶的二氧化硅粉尘的产品的特性。
本发明的第二任务是提供物品,所述物品在不使用石英的情况下制成,但是所述物品在外观和性能方面具有类似于包含石英并且在机械加工操作期间不产生结晶的二氧化硅粉尘的产品的特性。
该目的和任务在使用根据权利要求1的骨料的情况下、用根据权利要求9的方法和用根据权利要求19的物品来实现。
本发明的优点和特性特征将从在下文通过非限制性实例的方式提供的实施方案的多个实例的详细描述中更清楚地呈现。
特别地,已经出现的构思是在用于制造呈板或块形式的物品的方法中,使用非常硬的且半透明的或发白的、具有类似于石英的外观、但包含大体上仅呈无定形形式的二氧化硅的合成骨料和填料,而不是使用从石英的碾磨获得并且在机械加工操作例如切割期间可能造成上述问题的骨料和/或填料。
基本上,已经出现的构思是使用非常硬的且半透明或发白的、具有类似于石英的外观、但包含大体上仅呈无定形形式的二氧化硅的合成骨料和填料,而不是使用在(板或块)机械加工工艺期间将产生结晶的二氧化硅粉尘的石英。
包含大体上仅呈无定形形式的二氧化硅的合成骨料和填料可以是特殊的无定形玻璃,在技术术语中被称为“玻璃料”,其是非常硬的且半透明的或发白的、具有类似于石英的外观;可以存在痕量的呈结晶形式的二氧化硅,但在任何情况下以小于按重量计1%的量。
具有这些特性的玻璃料可以通过在约1550℃熔化选择的天然矿物粉末的混合物来获得。从熔化炉中输出的熔融材料被水射流直接撞击用于迅速冷却,然后干燥、碾磨并且分离成期望的粒度测定的级分(granulometric fraction)。
较细的粒度测定的级分被用作填料。
根据本发明的可能的实施方案,包含大体上仅呈无定形形式的二氧化硅的具有硬度≥5莫氏硬度的合成骨料和填料可以形成初始混合物中的骨料和填料的按重量计至少70%。有利地,包含大体上仅呈无定形形式的二氧化硅的具有硬度≥5莫氏硬度的合成骨料和填料可以形成初始混合物中的骨料和填料的在按重量计70%和按重量计100%之间。
有利地,所使用的具有硬度≥5莫氏硬度的玻璃料可以具有以下化学组成:
-48%<SiO2<73%,
-12%<CaO<30%,
-1.5%<MgO<11%,
-1.0%<Al2O3<19%,以及
-0%<ZrO2<20%。
或者所使用的具有硬度≥5莫氏硬度的玻璃料可以具有以下化学组成:
-43%<SiO2<80%,
-5%<CaO<30%,
-0%<MgO<12%,
-0%<Al2O3<25%,以及
-0%<ZrO2<20%,
-0%<Na2O<12%,
-0%<K2O<10%。
任选地,玻璃料还可以包含以下另外的组分:
-0%<B2O3<10%、
-0%<ZnO<10%,
-0%<BaO<10%,
-0%<Li2O<5%,
-0%<P2O5<5%。
有利地,具有硬度≥5莫氏硬度的玻璃料可以具有颜色,所述颜色具有高白度(其中L>95),或者是半透明的。这些颜色类似于已知类型的初始混合物中使用的石英的颜色。
为此目的,发色团的量必须特别低,使得上述化学组成还可以包括:
-Fe2O3<0.1%;以及
-TiO2<0.1%。
玻璃料颗粒物的硬度可以优选地大于5莫氏硬度,并且甚至更优选地大于6莫氏硬度。
此外,所使用的玻璃料是耐酸的(除了氢氟酸),并且对强碱具有良好的耐性。此外,所使用的玻璃料的特征为总的化学惰性和完全的水不溶性(即使在热条件下),也不需要另外的热处理。有利地,没有可能存在的任何金属的释放。
此外,所使用的玻璃料在碾磨期间具有良好的收率,其中当碾磨时具有产生粉尘或薄片(flake)的有限趋向。
用于生产板的方法的其他步骤保持大体上与现有技术相同。
在初始混合物已经被制备之后,其被沉积在临时保持器内部,所述临时保持器可以是所谓的托盘模具(在板的情况下)或模壳(在块的情况下)。
然后,混合物的表面可以覆盖有一层类似于形成托盘模具的材料的材料,或者在用于生产块的模壳的情况下覆盖有盖(lid)。
然后,包含混合物的保持器被插入到钟状物(bell)内部,在钟状物内部产生真空并且使混合物经受经由压力机压头(press ram)的真空振动压缩。
有利地,产生的真空可以具有在10毫巴和25毫巴之间的残余压力。有利地,真空振动压缩可以持续在30秒和70秒之间。
在振动压缩操作已经完成之后,恢复大气压力并且打开钟状物。
然后,在其中使用树脂作为粘合剂的情况下,板被转移到催化烘箱中,或者在其中使用胶结粘合剂的情况下,板被留下固化。
在物品已经被硬化之后,从保持器中取出物品,并且将所述物品传送出去,用于精加工操作(finishing operation)。
因此,与用于根据现有技术制造呈板或块的形式的物品的常规方法相比可以获得的优点是明显的。
首先,可以生产具有高品质外观并且耐刮擦和耐化学剂的物品,所述物品在机械加工操作例如切割期间不导致呈结晶形式的二氧化硅粉尘的形成。
其次,通过防止该组分的形成,可以预先避免操作者在机械加工操作期间的任何不正确的行为的后果。
此外,可以获得具有与用石英实现的美学特性、机械特性和性能特性非常相似的美学特性、机械特性和性能特性的板,其目前的市场是非常广泛的且在市场上是受欢迎的。
为了满足特定的需求,本领域技术人员可以对上文描述的实施方案进行修改和/或用等效的要素替换所描述的要素,而从而不偏离所附权利要求的范围。
Claims (29)
1.具有石材样外观的合成骨料和填料在用于制造呈板或块的形式的物品的方法中的用途,所述物品通过一定方法获得,在所述方法期间,包含骨料和任何填料以及粘合剂的初始混合物经历真空振动压缩,随后是包括所述粘合剂的硬化的步骤,其特征在于,所述合成骨料和填料具有大于或等于5莫氏硬度的硬度并且包含大体上仅呈无定形形式的二氧化硅,呈结晶形式的二氧化硅以小于按重量计1%的量存在。
2.根据权利要求1所述的用途,其特征在于,包含大体上仅呈无定形形式的二氧化硅的所述合成骨料是玻璃料。
3.根据权利要求1所述的用途,其特征在于,所述合成骨料和填料形成所述初始混合物中的所述骨料和填料的按重量计至少70%。
4.根据权利要求1所述的用途,其特征在于,所述合成骨料和填料形成所述初始混合物中的所述骨料和填料的在按重量计70%和按重量计100%之间。
5.根据权利要求1所述的用途,其特征在于,所述合成骨料和填料具有以下化学组成:
48%<SiO2<73%,
12%<CaO<30%,
1.5%<MgO<11%,
1.0%<Al2O3<19%,以及
0%<ZrO2<20%,
所述SiO2大体上仅以无定形形式存在,并且在任何情况下,其中呈结晶形式的SiO2的可能含量小于按重量计1%。
6.根据权利要求1所述的用途,其特征在于,所述合成骨料和填料具有以下化学组成:
43%<SiO2<80%,
5%<CaO<30%,
0%<MgO<12%,
0%<Al2O3<25%,以及
0%<ZrO2<20%,
0%<Na2O<12%,
0%<K2O<10%,
所述SiO2大体上仅以无定形形式存在,并且在任何情况下,其中呈结晶形式的SiO2的可能含量小于按重量计1%。
7.根据权利要求5和6所述的用途,其特征在于,所述合成骨料和填料的化学组成还包括以下另外的组分:
0%<B2O3<10%,
0%<ZnO<10%,
0%<BaO<10%,
0%<Li2O<5%,
0%<P2O5<5%。
8.根据权利要求5、6、7所述的用途,其特征在于,所述组成还包括Fe2O3<0.1%和TiO2<0.1%。
9.用于制造呈板或块的形式的物品的方法,所述物品通过一定方法获得,在所述方法期间,包含骨料和粘合剂的初始混合物经历真空振动压缩,随后是包括所述粘合剂的硬化的步骤,其特征在于,它包括具有大于或等于5莫氏硬度的硬度的合成骨料和填料,所述合成骨料和填料包含大体上仅呈无定形形式的二氧化硅。
10.根据权利要求9所述的方法,其特征在于,骨料和填料的按重量计至少70%由具有大于或等于5莫氏硬度的硬度的合成骨料和填料组成,所述合成骨料和填料包含大体上仅呈无定形形式的二氧化硅。
11.根据权利要求10所述的方法,其特征在于,所述合成骨料和填料形成所述初始混合物中的所述骨料和填料的在按重量计70%和按重量计100%之间。
12.根据权利要求10所述的方法,其特征在于,合成骨料是具有以下化学组成的无定形玻璃料:
48%<SiO2<73%,
12%<CaO<30%,
1.5%<MgO<11%,
1.0%<Al2O3<19%,以及
0%<ZrO2<20%,
所述SiO2大体上仅以无定形形式存在,并且在任何情况下,其中呈结晶形式的SiO2的可能含量小于按重量计1%。
13.根据权利要求10所述的方法,其特征在于,所述合成骨料和填料是具有以下化学组成的无定形玻璃料:
43%<SiO2<80%,
5%<CaO<30%,
0%<MgO<12%,
0%<Al2O3<25%,以及
0%<ZrO2<20%,
0%<Na2O<12%,
0%<K2O<10%,
所述SiO2大体上仅以无定形形式存在,并且在任何情况下,其中呈结晶形式的SiO2的可能含量小于按重量计1%。
14.根据权利要求12和13所述的方法,其特征在于,所述合成骨料和填料的化学组成还包括以下另外的组分:
0%<B2O3<10%,
0%<ZnO<10%,
0%<BaO<10%,
0%<Li2O<5%,
0%<P2O5<5%。
15.根据权利要求12、13、14所述的方法,其特征在于,所述化学组成还包括Fe2O3<0.1%和TiO2<0.1%。
16.根据权利要求9所述的方法,其特征在于,使用的所述粘合剂具有有机性质。
17.根据权利要求16所述的方法,其特征在于,使用的有机粘合剂是不饱和聚酯树脂。
18.根据权利要求9所述的方法,其特征在于,使用的所述粘合剂具有胶结性质。
19.用包含骨料和粘合剂的初始混合物获得的物品,所述初始混合物经历真空振动压缩,随后是包括所述粘合剂的硬化的步骤,其特征在于,所述物品包含具有大于或等于5莫氏硬度的硬度的合成骨料和填料,所述合成骨料和填料包含大体上仅呈无定形形式的二氧化硅,并且在任何情况下,其中呈结晶形式的SiO2的可能含量小于按重量计1%。
20.根据权利要求19所述的物品,其特征在于,骨料和填料的至少70%由具有大于或等于5莫氏硬度的硬度的合成骨料和填料组成,所述合成骨料和填料包含大体上仅呈无定形形式的二氧化硅。
21.根据权利要求20所述的物品,其特征在于,所述合成骨料和填料形成所述初始混合物中的所述骨料和填料的在按重量计70%和按重量计100%之间。
22.根据权利要求19所述的物品,其特征在于,所述合成骨料和填料由玻璃料组成。
23.根据权利要求22所述的物品,其特征在于,所述玻璃料具有以下化学组成:
48%<SiO2<73%,
12%<CaO<30%,
1.5%<MgO<11%,
1.0%<Al2O3<19%,以及
0%<ZrO2<20%,
所述SiO2大体上仅以无定形形式存在,并且在任何情况下,其中呈结晶形式的SiO2的可能含量小于按重量计1%。
24.根据权利要求22所述的物品,其特征在于,所述玻璃料具有以下化学组成:
43%<SiO2<80%,
5%<CaO<30%,
0%<MgO<12%,
0%<Al2O3<25%,以及
0%<ZrO2<20%,
0%<Na2O<12%,
0%<K2O<10%,
所述SiO2大体上仅以无定形形式存在,并且在任何情况下,其中呈结晶形式的SiO2的可能含量小于按重量计1%。
25.根据权利要求23和24所述的物品,其特征在于,所述合成骨料和填料的化学组成还包括以下另外的组分:
0%<B2O3<10%,
0%<ZnO<10%,
0%<BaO<10%,
0%<Li2O<5%,
0%<P2O5<5%。
26.根据权利要求23、24、25所述的物品,其特征在于,所述玻璃料还包括Fe2O3<0.1%和TiO2<0.1%。
27.根据权利要求19-26中任一项所述的物品,其特征在于,使用的所述粘合剂具有有机性质。
28.根据权利要求27所述的物品,其特征在于,使用的有机粘合剂是不饱和聚酯树脂。
29.根据权利要求19-26中任一项所述的物品,其特征在于,所述粘合剂具有胶结性质。
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