DE2023121A1 - Structured cladding panels and processes for creating structured surfaces - Google Patents

Description

Jöhns-Manviiie Corporation, 22 East 4th Street, New York 16, N ₀ Y., U. S ₀ A ₀

Textured trim panels and methods of manufacture structured surfaces.

For this application, the priority of US ₀ patent application university no. 821,810 of May 5, 19G9 claimed.

The invention relates to structured cladding panels and to a method of making it look more lifelike stone-like, structured surfaces on a cement-like board or the like.

Asbestos-cement linings and panels have been around for a number of years as architectural cladding in the form of wall cladding, roof coverings and side shingles, veneered table surfaces and the like used. The coloring of such claddings is usually determined by a suitable coating material or can also be added to the material as an admixed dye, with the visible exposed Surfaces additionally embellished by structuring measures or obeiflachenverede it can be. The design of such claddings has recently become more and more like this

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designed that the appearance of the surface panels on Closes natural products. At Äsbestzeiientprodukte goes the general trend towards structuring that resembles that of polished stones in appearance. It is However, it is relatively difficult to obtain true-to-life reproductions of stone structures in asbestos cement tiles, because during the hardening or the final manufacturing process in the manufacture of such panels or the like the surface the appearance of the so-called. "Blooming" or "Rejects" brings forth. During the manufacturing process

/ en the asbestos cement panels in a Äutociav at increased Temperature applied with steam, wherein calcium silicate hydrate developed, which then in the form of a! is present on the surface of the cement board. This water-insoluble Precipitation on the surface of the finished product gives it a matt, dark white appearance. The through the so called "blooming" caused excretion resembles a layer of white lime dust and is called so-called "steam treatment blooming" (steam cure bloom) known. In an ordinary hardening or post treatment toei of the asbestos cement panels, after they have been formed and exposed to the air for a few days (similarly 28 days), the imagination develops Calcium carbonate precipitate can also be used in a Ordinary post-treatment of the asbestos cement panels this one Carbon dioxide atmosphere under pressure and in the presence of moisture. The resulting precipitations also resemble a layer of white lime dust,

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as. So-called carbonate bloom (carbonate bloom or normal cure bloom) is known: "One way to prevent" blooming "is to process the panels appropriately before hardening, so that this phenomenon can be inhibited -" The finished panels treated in this way however, they have an appearance that does not match that of natural stones. Its surface structuring can that of stone structuring similar ₀ In previously known design ^ shape the color, the shape and appearance of the surfaces are too uniform and sterile

If-the known method of inhibiting the so-called Blooming effect is not applied, the excretion or precipitation covers the entire surface, so that an effect resembling the appearance of a stone only slightly or not at all is achieved »Attempts at Removal of the precipitate are carried out with appropriate solvents, for example with hydrochloric acid or ammonium bifloride been «, also mechanical processes using sand which has been introduced or by means of sandblasting Is used, are known «These known methods remove the precipitate known under "blooming" in a more satisfactory manner Way on flat, level plates, but do not show satisfactory results when machining: ' tion of structured boards. In general, it is of the practical From the point of view, impossible, the precipitation

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by sanding without damaging the structure of the surface to remove uniformly. In addition to this, the known method using sand is with asbestos cement therefore particularly disadvantageous because the asbestos fibers that directly adjoin the surface, be injured in the process. The use of a suitable solvent is also possible disadvantageous, since this etches the surface of the board and thereby the fiber structure immediately adjacent to the surface is also destroyed and exposed. In addition, is it is difficult to treat the deeper sections of the structured surface with the solvent used in the same way to be reached like the higher parts »Apart from the sand or solvent treatment to remove the surface The structured J treated in this way have surface precipitation

In conclusion, cement boards do not have the required appearance. The> known surface treatments achieve an appearance which; indicates too clearly artificial structuring.

The invention is based on the object of a method for Manufacture of cementitious panels, preferably asbestos cement panels to develop which, in the case of structured surfaces, give the panels a final, sufficiently lifelike, gives an appearance comparable to stone surfaces

The solution to this problem is achieved according to the invention by that the surface of the board before its final hardening jbzw. is structured before the follow-up treatment in such a way that it

i has raised and low surface areas that the -5-.!

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Panel of an after-treatment for hardening the same und, drawn being a deposit known as "blooming" or Precipitation on the structured surface shows that the structured surface is polished with a pliable and compressible abrasive material in such a way that the raised and deeper lying areas are brought into contact with the grinding material, the contact pressure of the abrasive material varies in such a way that the deposition from the higher-lying parts and to the left of the lower-lying parts

cut a noticeable contrast to the structured surface between the coloring of the most essential parts of the structured surface, is removed.

An advantage of the process of the invention is that it is readily within conventional manufacturing processes preferably from asbestos cement panels with a minimum Can be applied effortlessly and without difficulty.

The essence of the invention is explained below with reference to the enclosed Drawings described, with further from the description Features and advantages of the invention emerge and the drawings mean in detail:

Fig. 1 is a perspective schematic plan view

on a structured board or cladding panel.

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2 shows an enlarged sectional representation a structured board, where the surface is referred to as "Blooming" coated well-known precipitation

is.

3 shows a simplified representation of the method to remove the! precipitate from the

Surface ο

FIG. 4 is an enlarged broken cross section taken along line 4-4 of FIG.

Figo 5 is a sectional playback in accordance with Figure 2 _e, wherein the precipitate

removed from the polished surface j

ι is.

The term "blooming" used in the description describes either a precipitate consisting of water-insoluble Calcium silicate hydrate consists, and that during the steaming phase occurs or from a precipitate of water-insoluble calcium carbonate deposited on the surface of the cement-like product is excreted during a normal post-treatment process, namely by the fact that this one Carbon dioxide atmosphere is exposed under pressure in the presence of moisture. bad ORIGINAL

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j In F-l ·; - "· 1 an asbestos cement board or board 10 is shown, whose surface in accordance with that

\ is structured by stones ο The structuring,., consists of ι ■ ■

in irregularly formed, raised sections 12 and

; deeper Fläciienteilen 14. Some portions of the surface are gradually slanted with respect to the high and low portions and between said portions such as the portion 16 ₀ are provided in the struc ~ turing between the raised and the lower-lying sections edge-like formations, so that this results in talartic areas 17 and pockets or crevices 19

can
As mentioned above, a lifelike reproduction of the stone structure cannot be achieved if the coloring of the stone is completely constant and the surface

shows no changes in its appearance,

A structured asbestos-cement sheet, which is made from a corresponding raw material mixed with water, is shown in introduced into the cavity of a disk press. Openings provided within the cavity of the press make this possible Squeezing out the water during the pressing process so that the material compacts and into a final shape and thickness is brought «The pressing process is carried out in such a way that the product obtained is dry enough to maintain the pressed-in shape prior to the drying process «The desired Structuring can be found in the stamps of the

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Disc press and the damp asbestos cement mix becomes one exposed to such pressure that the required proportion of water is pressed out of the mixture and thereby a permanent pressing of the structure into the surface of the asbestos-cement board takes place »The sheet is then removed from the press and subjected to a curing process or a corresponding post-treatment and drying.

During the aftertreatment, the will form on the surface : manufactured board water-insoluble calcium silicate hydrate,

which occurs in the process step of steam treatment! or even water-insoluble calcium carbonate in the event of the j normal follow-up treatment. This water-insoluble product is similar

a slight coating of lime dust in its appearance. A part of such a table is shown in Figo 2, the entire table consists of elevated and lower-lying sections, which act as a whole with the so-called "blooming" 20

are. As shown in the illustration, this surface f- ; knock down the board to give it an appearance I which is comparable to that of natural stones, so that the product is unsuitable for the intended use «

According to the invention, the "blooming" on the surface of the panel i
not completely removed, as was the case with previously known

Procedure has been carried out, but the obef-flatbe-

Rather, the action takes place in such a way that the elimination of the downpour

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The method for removing the precipitate can preferably be seen in the illustration in FIG. Table .10 is j along a structured surface labeled as "blooming" designated precipitate and is in this form! on a continuously moving conveyor 22 lying below 'passed through a grinding device. The conveyor 22 moves here over the rollers 24 and 26. At a distance over ! the support surface of the conveyor 22 is rotatably supported by a shaft 28

i ·

strengthens, on which a plurality of ring-like resilient abrasive pads or corresponding segments 30 are arranged. ! Matching clamps 32 hold the individual cushions in opposition to one another and are for this purpose on the end faces of the outer

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Upholstery attached. The plurality of tier individual pads 30 form -together a sanding roller that extends from one edge of the Plate 10 extends to the other. The abrasive material of the upholstery j30 consists of a relatively fine material, which remove both the deposit from parts of the upper surface of the board, as well as polishing the board must ensure «

The grinding effect is such that residues of the I -

the term "blooming" denotes precipitation on the surface remain undamaged or that only very insignificant sections of the asbestos-cement sheet are removed. Here it is It is important that no significant amounts of the asbestos-cement composition are removed, so that by no means the immediately below exposed fibers of the asbestos scene panel lying on the surface will. For this purpose, the ►abrasive material must have a suitable flexibility having the thickness of the pad or brush.

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is selected such that the compressible material with the higher as well comes with the deeper sections of the patterned surface of the panel in contact · _o The pressure exerted by the abrasive material on the surface must be larger at the higher part section than in the lower ^ ele ^ en areas in order to remove the precipitation as completely as possible from the former,

The mode of operation of the grinding roller 34 is based in particular on Representation in FIG. 4 shows * The outer peripheral machining surface of each grinding segment 30 engages in the structured Surface of the board 10 and is located here with both the highest and the lowest points of the surface in contact. This is possible when the wave ^ on

which the individual segments 30 are attached, in one!

ί runs constant distance over the conveyor, since the grinding j

material is compressed to a greater extent at those places where it is in connection with the higher sections of the structured surface. This means that there is a higher pressure from the sanding roller on the high sections of the structured surface than on the low areas! and consequently more precipitation is removed from the higher sections than from the lower areas. The higher areas are also preferably subjected to a stronger polishing action than the lower areas. Furthermore, those surface sections like etiva die

Sections 10 in a graduated descending manner with changing «! Pressure applied to the sanding roller, where —11—

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this ν η the high-lying parts 12 up to the valley-like

'Sections 14 falls. As a result of such an arrangement

ί and mode of action, a corresponding residual amount of the low

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dersciilages back on the lower section, while 'Essentially no precipitation on the highest section The structured surface is present after this treatment is and finally a correspondingly graduated reduced Amount of precipitation between the highest and lowest; Sub-areas of the surface section 16 is recorded o

In Fig., 5 reproduced part of the inventively treated panel is to be compared with the illustration of FIG _o 2, wherein the latter view has not yet been subjected to the method eirfindungsgemäßen _o

As from F ¹ Ig. 5, the precipitate is removed from the higher parts of the structured surface, while it has remained essentially in the lower-lying areas which immediately adjoin the higher areas. A graduated abrasive effect can be seen at the connection points between the higher sections and the lower-lying areas of the surface, as indicated, for example, on the surface area 16. The textured surface obtained produces an appearance that exactly matches that of a natural stone, preferably with stones whose basic color matches that of the asbestos-cement mixture, for example brown or gray natural stones.

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An example of a suitable abrasive material that can be used to remove the precipitate and at the same time polish the surface of the asbestos-cement sheet is ring-like abrasive segments sold by Minnesota Manufacturing and the Mining Company under the tradename "skotch brite ^11. These abrasive segments consist of a nylon fabric to which abrasive particles are applied, such as aluminum oxide, silicon carbide, or silica particles bound to the fibers of the material. The fiber material receiving the abrasive particles can also be in the form of a belt or band. Such embodiments are for example made by the American company Armor Abrasive Company sold under the trademark "Microion".

The invention is not limited to the use of abrasive material which has a single grain size, especially

φ the type of structuring and the final desired surface design as well as their appearance can be very different and from the intended use of the product and also depends on the individual taste of the buyer. A special one suitable grinding and polishing material has a grain size of 280, this being the one on the surface of the Panel formed precipitate is removed in a suitable manner, as well as a polishing of the cementitious material in a very good way in a satisfactory way «

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In addition, the invention is not limited to the use of such abrasive materials which consist of a fibrous matrix or the like, the abrasive particles being bonded to the individual fibers. The polishing effect can also be achieved by a material which is able to carry out the grinding process at the same time and which has the corresponding suppleness and resilience for this purpose. A suitable material for this is, for example, steel wool with a fine graduation. Due to the very different nature of the abrasive material that can be used, this expression is to be understood in the description as well as in the patent claims to include both particles bound to a resilient, pliable and resistant matrix and a compressible material which can be used without impact is self-abrasive with particles, can act.

It is not advisable to limit the pressure to be applied to the board to be polished, as the surface finishing process can be carried out at very different pressures, depending on the type of abrasive material as well as the structure of the board, the composition of the asbestos-cement material or personal taste is dependent. It can for example be necessary to use a very fine abrasive material, and "on the surface of the panel aina appropriate -

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Achieve impact while making a bigger one Pressure would be applied to it than when using coarser abrasive material. In addition, changes, As described above, the contact pressure of the grinding device depending on the shape of the surface of the Board during the grinding process in accordance with the structuring ·. In this case, those areas of the area which are relatively high, greater pressure than in the lower areas. Depending on too Achieving surface effect can have different pressures and different abrasive materials are used, whereby as a condition it must always be ensured that the Abrasive material is pliable and compressible, and that it is also of sufficient thickness that ensures the penetration of the abrasive material, even in deeper areas of the structured surface.

In an application example of the Ver inventive driving asbestos cement sheets are used, which consist in their dry weight composition of about kO% Portland cement, k5% asbestos fibers and 2.5% of silica or Silikatmefcrl and mixed with water form a mixture containing about 25% solids. The raw material mixed in this way is filled into a © disc press, the press plate of which has the desired structure, approximately

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corresponds to the appearance of slate. The pressed panels have an oversize - with regard to their thickness - of 3i2 mm and are subjected to sand on their backside before the panels are subjected to a steam treatment. The panels were exposed to air for seven days in order to be subsequently freed from the backward sanding, namely initially by means of a reduction in thickness of 1.6 mm. The panels treated in this way were then provided on a pallet with a protective material, such as soft foam, which is placed between the adjacent panels in order to prevent them from being crushed or broken and the structure in general from being damaged. The panels were steamed at a pressure of about 7 kg / cm ^ (100 psi) for 16 hours. This treatment was followed by a drying period of 8 hours at about 121 ⁰ C. After drying was complete, the back of the panels was completely freed from the sand and the remaining 1.6 mm of the specified oversize was removed. The structured surface of the board was then subjected to the treatment of the individual segments of the grinding shaft, which consists of the aforementioned "skotch-brite" material made of nylon fabric with aluminum oxide bonded to it with a grain size of 28θ. The appearance of the asbestos-cement boards was the same

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Sufficiently true-to-life slate with a charcoal-like color effect »During the grinding process, about 90 to 95% of the so-called" blooming ¹¹¹¹ "precipitation was removed, with the small amount of precipitation remaining on the surface causing the true-to-life effect» Often it is desirable to use the to cover the structured surface with a colorless varnish in order to achieve a corresponding weather resistance. Such a requirement exists in particular when the panels are used as cladding in the construction industry in an environment that is frequently subject to changing weather conditions. For example, as a suitable varnish coating, which is sprayed onto the boards, a cellulose acetate butenate, which is diluted with two parts of methyl ethyl ketone, can of course be used, depending on personal taste and conditions Be different »In this connection it has been found that a coating of around 10 grams per 9.29 dm ⁴¹ is particularly suitable.

Although only the production of an asbestos cement product has been presented as an exemplary embodiment in the description, the invention is of course not restricted to the use of such a material;

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are subjected to similar treatment insofar as the surface of the same has the effect of so-called "blooming" produces and · the selected structuring a different removal of this precipitate by means of the described grinding process enables. The width the structure can be different depending on the taste. However, the difference between the The highest and deepest surface sections can still be chosen so that the grinding process in the above-described Shape can expire. The height difference should not be more than about 6.35 mm.

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Claims (2)

202312 PATEITAISPBfG IE 1o) Process for the production of lifelike looking, stone-like structured surfaces on cement-containing boards, such as asbestos-cement boards, characterized in that the structuring of the Safeloberflä® is introduced before the post-treatment (yours) in the form of raised and lower surface areas, that the post-treatment or "The hardening of the panels brings about the process of so-called" blooming ", that is _, a precipitate is deposited on the structured surface ₉ that the structured surface is treated with a flexible, compressible abrasive material so that the high and low areas are treated at different pressures in bond with the abrasive material are, so that the precipitate vorzugsi-Jeise from the higher sections and left of the lower Enrich the structured surface § © iffioa! Contrast between the color tone of the main sections and d © r structured surface eraielead, entferat " BATHROOM ORIGINAL - 19 - 00 ^ 847/1310 2.) The method according to claim 1, characterized in that the abrasive material a pliable compressible Has Katrix made of fiber material, on which a relatively fine-grained abrasive is bonded. 3 ·) '/ experienced according to claim 1 and 2, characterized in that that the panels are asbestos fibers and the hydrothermal reaction product of a hydraulic cement and silicate and include lime. Patent attorneys Seiler u, Pfenning BATH 0098 47/1310