DE19938806A1 - Surface finished concrete blocks are connected using a polymer artificial stone layer containing of colorless or colored unsaturated polyester resin or vinylester resin as binder - Google Patents

Abstract

The polymer artificial stone layer consists of colorless or colored unsaturated polyester resin or vinylester resin as binder; ground used glass and/or aluminum hydroxide and/or other transparent or opal-like light material of mineral origin; transparent used glass granules as fine filler; and colored used glass granules as main filler. Polymer artificial stone layer consists of 10-25 wt.% colorless or colored unsaturated polyester resin or vinylester resin as binder; 10-20 wt.% ground used glass and/or aluminum hydroxide and/or other transparent or opal-like light material of mineral origin as fine filler having a grain size of 0-0.05 mm; 10-30 wt.% transparent used glass granules as fine filler having a grain size of 0.05-0.5 mm; and 40-70 wt.% used glass granules having a grain size of 0.3-4 mm which were colored as main filler using an aqueous dispersion of polyvinylacetate and (preferably inorganic) colored pigments on the surface. An Independent claim is also included for a process for the production of the concrete blocks comprising pouring the above polymer stone composition into a polypropylene or polyethylene mold and pressing the heated concrete block onto the composition so that an inseparable join between the block and the artificial stone layer is produced.

Description

The present invention relates to the refinement of the sight and usage or tread surface of concrete blocks by applying a polymer art stone layer, which is made of colored coated glass granulate as appearance-defining filler, colorless waste glass fine granules as Fine filler, colorless waste glass powder and / or aluminum hydroxide and / or another transparent or opal-like light mineral material Origin as a fine filler and unsaturated polyester resin (UP resin) as Binder exists.

Over the past 150 years, the Building the natural stone more and more of cement-bound concrete repressed. Today, for example, public sidewalks and squares, Private garden paths, terraces and courtyard or park areas mostly not more paved with natural stones but with concrete stones.

At the same time, it can be observed that efforts are being made today to: gray concrete to take its dreary charisma by Usable surface of the concrete block is colored and refined in this way is that in terms of color and grain structure it is more like natural stone than at Concrete should remember.

This finishing is usually done by applying a cement bound so-called "natural stone header". This is often under Use of pigment-colored cement - difference between natural stone chips colors are homogeneously combined with the concrete block. In another Work step, the stone surfaces are water-blasted, with soft Fine concrete parts are washed out, leaving the individual aggregates remain sublime. In other cases, a similar effect is brought about Sandblasting reached the surface.

However, the aesthetic gain that surface-treated concrete blocks experience in this way is offset by disadvantages in terms of their usage properties:

• - The user surface is rough and porous: it favors the accumulation of dirt in the washed out or sandblasted Indentations.
• - The porous surface favors in shady locations when moist Weather the settlement of mosses in these wells. It also allows chewing gum spit out into the wells cling tough.
• - It is absorbent towards liquids: especially oily or greasy, Hardly evaporable liquids are refined in the pores of the Preserved surface - e.g. B. in the form of ugly, by leaking Car engines caused old oil stains. Attempted cleaning, such as Steam jets with a high pressure cleaner easily lead to one Damage to the surface, loss of color and reduced lifespan entails.

The invention has therefore set itself the task of surface finishing to design the concrete blocks so that the disadvantages of dirt, moss and Liquid sensitivity can be avoided, but at the same time that natural stone-like appearance is further enhanced.

It has been found that this is possible by inevitably applying a 3-10 mm thick polymer artificial stone layer on the surface of the concrete block, which is composed as follows

• - As a binder: 10 to 25 percent by weight colorless or colored Unsaturated polyester resin (UP resin) and for processing required reactants and additives,
• - As a very fine filler: 10 to 20 percent by weight of transparent waste glass powder and / or aluminum hydroxide and / or another transparent or opal-like light material of mineral origin in the grain size range less than 0.05 mm,
• - As a fine filler: 10 to 30 percent by weight of uncoated, transparent Used glass granulate in the grain size range 0.05-0.5 mm,
• - As an appearance-determining filler: 40 to 70 percent by weight of waste glass granules in the grain size range 0.3 to 4 mm, which by means of a aqueous dispersion of polyvinyl acetate and (preferably inorganic) Color pigments were colored on the surface in targeted shades.

DE 44 02 432 describes a polymer resin and partially colored Surface-coated waste glass granules composed of polymer artificial stone. However, the document does not answer the question of whether, under what requirements and according to which procedure this material as Facing layer can be inseparably connected with a concrete block.

The present invention concentrates on precisely this question.

It has been found that there is an inseparable connection between concrete block and old glass-filled polymer artificial stone finishing layer according to the following Process can be produced efficiently:

The still unhardened polymer stone mortar, consisting of -

• - 10-25% by weight of reactive, colorless or colored UP resin as a binder,
• - 10-20% by weight of transparent waste glass powder or aluminum hydroxide or another transparent or opaque light minerali material origin as a fine filler in the grain size range below 0.05 mm,
• - 10 to 30% by weight of uncoated, transparent waste glass granulate in the Grain size range 0.05-0.5 mm as fine filler
• - and 40 to 70% by weight of waste glass granulate in the grain size range of 0.3 to 4 mm as an appearance-determining filler, this Granules with an aqueous dispersion of polyvinyl acetate and (preferably inorganic) colored pigments -

- is placed in a mold with the desired surface structure and distributed under vibration.

Then the - previously heated to a temperature of 40-70 ° C - Concrete block pressed onto the still soft polymer stone mortar layer.

The contact with the warm concrete block under pressure causes the UP resin contained in the polymer stone mortar is still thin for a short time becomes more fluid and therefore easier even in fine pores of the concrete block can penetrate.

But then the heat of the stone causes acceleration and Intensification of the polymerization process. The resin hardens so quickly that the product can be removed from the mold after only a few minutes.  

It is advantageous to use molds made of polyethylene or polypropylene, which are heat-resistant up to a temperature of 90 ° C.

Because these materials differ very easily from hardened polyester artificial stone separate, it is not necessary to enter a release agent into the mold. Both Materials also promote non-tacky curing of the polyester art stone surface, so that the solvent is removed at the time of demolding is resistant.

The concrete blocks finished by the process according to the invention are characterized by the following properties:

• - They can be more similar to natural stone in terms of grain structure and colors be designed as this with cement-bound finishing layers is possible.
• - The connection between the concrete block and the glass-filled one Polyester artificial stone layer is inseparable. If you try e.g. B., this layer knocking off with a hammer, this leads to breaks in the Overall material, but not to detach the polyester artificial stone layer from the concrete.
• - The glass-filled polyester artificial stone layer improves the mechanical Strength of the entire material, this applies particularly to the bending strength, tensile strength and impact resistance.
• - The surface is very abrasion-resistant and does not dust.
• - The surface is resistant to solvents and largely resistant to chemical stress (salt solutions, dilute acids and propellant substances and oils).
• - The surface is non-porous - regardless of whether it is smooth or non-slip (e.g. slate quarry rough) is designed. It is therefore neither pollution still susceptible to moss.
• - The surface is weather and light resistant. When using lightfast UP resin and lightfast pigments also occur in the long term no color changes.  
• - The surface is due to the low water absorption of the glass-filled polyester artificial stone frost-resistant.
• - The product can be manufactured very efficiently and does not require any Post processing.

It is known that UP resins (like practically all polymeric binders) during the polymerization process of volume shrinkage subject to and also in the hardened state on temperature changes can react slightly expanding or contracting.

A focus of the invention was therefore to ensure that due to expansion behavior due to temperature changes not microscopic Cracks appear in the grain structure of the glass-filled polyester artificial stone.

Because such cracks not only cause a color change of the Material due to light reflections from the glass particles. They lead above all also to the undesirable formation of pores on the surface of the Polyester artificial stone layer.

DE 44 02 432 describes a method to make the material insensitive to changes in temperature: Here, the surfaces of the old glass splinters in the grain size range between 0.5 and 4 mm are provided with a coating, which is composed of:

• - an aqueous solution of alkali silicates (water glass) or one aqueous dispersion of acrylic copolymers or a mixture of these two substances as binders,
• - dye (preferably inorganic pigments)
• - as well as an outwardly compacting filling made of transparent and / or opal-like light fillers of mineral origin such as Glass powder, quartz powder, diatomaceous earth, talc, aluminum hydroxide or one Mixture of two or more of these fillers.

In contrast, the present invention provides a coating of the old glass splinters in the grain size range between 0.3 and 4 mm, which is composed of:

• - An aqueous dispersion of polyvinyl acetate as a binder
• - and dye (preferably lightfast inorganic pigments).

Comparative experiments have shown that polyvinyl acetate (PVAC) is just for UP resin-bonded, glass granulate-filled artificial stone layers, with a Solid bodies are more suitable than that in DE 44 02 432 material combination described.

This is because PVAC is not just excellent It also has adhesive properties to the glass splinters is much more elastic than water glass or most acrylic copolymers. The PVAC therefore not only serves as an adhesion promoter but also as Expansion buffer.

The PVAC layer also works with the UP resin surrounding the glass splinters an intimate connection: Of that contained in the uncured UP resin The PVAC layer is initially monostyrene on the resin-side surface solved.

Due to the rapid polymerization of the UP resin, however, the monostyrene has not enough time to penetrate the PVAC layer completely, because also the styrene, while it is still trying to eat into the PVAC, is transferred to the polymeric polyester chain built in and stripped of its aggressive potency. The result is a strongly "interlocking" material transfer from the UP resin to PVAC layer of the glass splinter. There is another way of proving the experiment amazingly strong coherence of the colored coated glass fragments themselves sudden temperature changes in the area that can be repeated any number of times do not explain between - 30 ° C and + 100 ° C.

Another advantage of glass splinter coating with PVAC is that Circumstances that - in contrast to the method described in DE 44 02 432 - No additional filling of the coating that compresses to the outside with transparent and / or opal-like light mineral fillers Is required to ensure good thermal shock resistance of the to ensure glass-filled polyester artificial stone.

The invention thus relates both to products - namely concrete blocks which are inseparably connected to a glass-filled polyester artificial stone layer and which look very similar to natural stone - and to a method for producing the same. This process is characterized in that:

• - firstly: the coarser glass granules used in the grain size range from 0.3 to 4 mm using an aqueous dispersion of polyvinyl acetate as binders and (preferably lightfast, inorganic) pigments be coated on the surface in targeted colors,
• - secondly: one essentially made from ground waste glass and reactive Ready UP resin existing polyester mortar layer without a release agent in one Form made of polyethylene (PE) or polypropylene (PP) and under Vibration is distributed - and:
• - third: a concrete block heated to 40-70 ° C on the polymerizations ready UP mortar layer is applied under mechanical pressure.

This invention is applicable to the manufacture of the following products: Terrace, courtyard and garden path slabs, paving and composite paving stones in public and private areas, so-called "eco-stone" systems (i.e. Paving stones with spacers for infiltration of rainwater), Grass pavers, table tops for outdoor use, plate-shaped Elements for swimming pool construction as well as clinker bricks and facade panels for lining walls.

Examples

Fig. 1 shows an inventive surface-finished concrete block immediately after removal from the mold:

Form (A) advantageously consists of polyethylene which can be heat-loaded up to 90 ° C or polypropylene, both materials that require the use of release agents make redundant.

The surface-finishing layer (B) is between 3 and 10 mm thick. she consists of a colorless or transparent colored UP resin as Binder, transparent glass powder or aluminum hydroxide with grain sizes less than 0.05 mm as fine filler, untreated waste glass granulate in grain size range from 0.05-0.5 mm as a transparent fine filler as well as targeted colored coated glass granulate in the grain size range from 0.3 to 4 mm as the main filler that determines the appearance of the surface.  

The glass particles of this main filler were colored on the surface using polyvinyl acetate as an elastic binder and lightfast color pigments. (see Fig. 2)

The concrete block (C) was applied to the surface finishing before application glass-filled polyester mortar heated to 40 to 70 ° C. When contacting the The warmth of the concrete block made the polyester binder thinner for a short time and was therefore able to penetrate fine pores of the concrete block surface. Immediately afterwards, however - accelerated by the heat of the concrete block - a rapid polymerization process, so that the product already after could be removed from the mold in a few minutes.

The heat that is still stored in the concrete block even after demolding works beneficial to the rest of the curing process, so that for the so-called "post-curing phase" no storage in one Room with elevated temperature is required.

Fig. 2 illustrates the structure of the greatly enlarged scrap glass filled Polyersterkunststeinschicht: The finely divided filler (D) is made of transparent and / or opal light material in the grain size range of less than 0.05 mm.

The fine filler (E) consists of transparent glass granules in the grain size range from 0.05 to 0.5 mm.

The appearance-determining main filler (F) consists of glass granulate in the Grain size range from 0.3 to 4 mm, which previously with an aqueous Dispersion of polyvinyl acetate (G) and (preferably inorganic) Pigments was color coated.

Fig. 3 shows the section through the edge area of the surface-refined concrete block: Since the heated concrete block was applied under pressure to the adhesive polyester mortar, the UP resin could penetrate deep into the pores of the concrete block (H). Concrete block and polyester artificial stone layer are thus inseparably interlocked.

The bevelled shape of the concrete block in the edge area (I) ensures ensuring that no refinement of the refined stone in the form of Deburring is required.

Claims (5)

1. Surface-refined concrete blocks, characterized in that the concrete blocks are inseparably connected with a polymer artificial stone layer consisting of:

• - 10-25% by weight of colorless or colored unsaturated polyester resin as a binder,
• 10-20% by weight of waste glass powder and / or aluminum hydroxide and / or another transparent or opal-like light material of mineral origin as a fine filler in the grain size range from 0 to 0.05 mm,
• - 10-30% by weight of transparent waste glass granulate as fine filler in the grain size range from 0.05 to 0.5 mm,
• - 40-70 wt .-% of waste glass granules in the grain size range of 0.3 to 4 mm, which was colored as the main appearance-determining filler by means of an aqueous dispersion of polyvinyl acetate and (preferably inorganic) color pigments on the surface in targeted shades.

2. Process for finishing concrete blocks, characterized in that a polymer mortar layer consisting of:

• 10-25% by weight of reactive, colorless or colored unsaturated polyester resin as a binder,
• 10-20% by weight of waste glass powder and / or aluminum hydroxide and / or another transparent or opal-like light material of mineral origin as a fine filler in the grain size range from 0 to 0.05 mm,
• - 10-30% by weight of transparent waste glass granulate as fine filler in the grain size range from 0.05 to 0.5 mm,
• - 40-70% by weight of waste glass granulate in the grain size range from 0.3 to 4 mm, which was colored as the main appearance-determining filler by means of an aqueous dispersion of polyvinyl acetate and (preferably inorganic) color pigments on the surface in targeted shades -

- Is placed in an open mold and then the dry concrete block is pressed from above, so that in the course of the polymerisation of the polymer mortar, an inseparable connection between the concrete block and the polymer stone layer is created. 3. The method according to claim 2, characterized in that the open Mold made of polyethylene or polypropylene to apply to a release agent to be able to do without. 4. The method according to claim 2, characterized in that the concrete block is heated to 40-70 ° C prior to pressing to complete the polymerization speed up the process. 5. Use of surface-finished concrete blocks according to claim 1 for the production of terrace, courtyard and garden path slabs, paving and Compound paving stones in public and private areas, so-called "Eco-stone" systems (i.e. paving stones with joint spacers for Seepage of rainwater), grass pavers, table tops for the Outdoor area, plate-shaped elements for swimming pool construction, Clinker bricks and facade panels for lining walls.