DE2408503A1 - Moulding synthetic stones blocks or plates - by subjecting the plastics impregnated aggregate in the mould to vibration prior to thermosetting - Google Patents

Abstract

Synthetic stones, blocks or plates composed of mineral particulate matl. impregnated with a thermosetting resin are produced by filling the mixt. into a mould and then vibrating the mixt. prior to thermosetting using heat and pressure. Stones etc. have a uniform density whereby the tensile, compression and bending properties of the stones are markedly improved.

Description

Method and device for the production of artificial stones and plates The present invention relates to an improved method of making Artificial stones and slabs made from mineral components and hardenable organic Binders, as well as a device for carrying out this process.

It represents a further improvement in one's own, older one Patent application P 19 51 547.o described method and for its implementation disclosed device.

According to the method disclosed in this earlier patent application mineral components are mixed with the hardenable organic binders, filled into appropriate molds, pressed and then cured with the addition of heat.

The products obtained in this way are characterized by very good strength properties from that far exceed the values of conventional materials based on inorganic Binders such as plaster of paris, cement and the like. Lie.

It has now been found that the properties of the artificial stones obtained and synthetic plates, in particular their strength properties, such as flexural strength and compressive strength, continue to be increased # ön # n, / if that is filled into the molds Mixture of mineral components and hardenable organic binders, is preferably subjected to a vibratory treatment before the application of pressure, and is cured during or after pressing at an elevated temperature.

Such a vibration treatment will make a better filling the shape, so that cavities, which are both inside the molded body, as well as on its surface, and thus to an impairment contribute to its strength properties, can be safely avoided without the Pressure treatment must be carried out for an excessively long time before curing.

Vibrations can be used for this vibration treatment, the frequency of which can vary over a very wide range. So are for example Vibrations with frequencies of 1 - 1000 Hz, preferably 5 - loo Hz for the Process according to the invention suitable.

The generation of these vibrations can be done mechanically, for example by means of an eccentric or by electromagnetic means.

The vibration treatment is carried out according to an advantageous embodiment of the present invention 1 - 600 sec.

carried out for a long time, and it can also be carried out during the filling process Use the form, as this facilitates the filling process and also the filling process in cavities trapped air can escape better.

The mixture pretreated in this way is then pressed, more advantageously Way with a pressure of 0.5 - 50 kp per cm2. During pressing, the Vibration treatment can also be continued.

Particularly advantageous results are obtained when prints Use which are in the upper part of the aforementioned range. this will in a simple manner with the inventive method described in detail below Device reached.

The curing of the mixture takes place at a temperature in the range of preferably 150-3ovo0 C, this curing temperature of course largely depends on the curable resins used.

The hardening time varies largely with the thickness of the artificial stone or the synthetic plate, since the heat transferred from the die takes a certain amount of time required to fully bring the material filled into the mold to the curing temperature to heat. Usually the curing times are of the order of magnitude from 10 to 30 min., preferably approx. 20 min.

requires. According to a particularly advantageous embodiment of the The method according to the invention is the mixture of mineral components and hardenable organic binders in an already heated to the hardening temperature Shape filled, the vibration treatment and the pressure treatment subjected and hardened by corresponding dwell in the mold. The on artificial stone or the artificial stone slab produced in this way is then expedient removed from the mold in the hot state, and the same can then be used again immediately New manufacturing cycle can be used without cooling the mold occurring.

In this way, the process according to the invention becomes much more economical designed and the energy supplied for the hardening of the plates can be quite considerable and the space requirements can be reduced.

It has also proven to be very advantageous when the mold before loading with the mixture of mineral components and hardenable organic binder is coated with a release agent. Such a release agent prevents the molded body from sticking to the mold wall. as Release agents can be any means customary for this purpose in structural engineering to be used.

After all, it has been especially useful when using one already The mold heated to the curing temperature has proven to be particularly useful if the mixed material of mineral components and hardenable organic Binding agents is poured into the mold in one go. Accordingly, the inventive The method is expediently carried out in such a way that the material removed from the mixer is filled into a metering vessel and from this metering vessel in one pour into the mold is filled, subjected to vibration and pressure treatment and cured.

In this way, a very uniform curing of the invention Artificial stones and plates achieved.

The inventive device for performing the above Method consists of a metering and Mixing device, one Press mold with ram and a heating device, and it is characterized by that the mold is arranged with respect to the ram so that the punch comes into effect on a small boundary surface of the compact.

So far it was common to use such artificial stones and stone slabs to manufacture in a horizontally arranged form with a vertical punch came to the effect on the largest boundary surface of the compact.

Because of the relatively large pressing area, it was possible to achieve high pressing pressures but only possible if in the press cylinder, which is usually hydraulically operated extremely high pressures came into play.

This disadvantage is avoided with the device according to the invention, so that relatively high pressures can be achieved even with conventional press rams.

The ram can be both vertical and horizontal Direction of the compact to act, the arrangement of the mold is preferably such that the pressed artificial stone slab in the vertical direction a narrow boundary surface. Such an arrangement of the mold facilitates removing the pressed body from the die and stacking it for Cooling-down-quite considerable, and especially in this way it becomes an afterthought Deformation of the still hot artificial stone plate avoided, which is the case with a horizontal arrangement of the plates occurs frequently.

The heat required for curing can be the mold and the arranged therein compact be fed in various ways.

However, it has proven to be particularly advantageous if in or Feed-through lines for the heating medium are provided on the wall of the compression mold are. The heating medium can consist of heated liquids or heated gases, in particular superheated steam.

A heating medium has proven to be particularly advantageous which consists of heated dl, which is heated in a separate heating device, and passed with a conveying device through the lead-through lines of the mold will.

A thermostat is expedient in this circuit of the heating medium provided, whereby a uniform temperature of the heating medium, and thus a uniform temperature of the mold is achieved. To increase profitability of the method according to the invention, it is expedient to use two or more compression molds to combine a die package.

Such a compression mold package can have corresponding filling openings at the same time with the mixture of mineral components and hardenable organic Binder charged, and by means of a special, subdivided press ram can fill the material into the various press chambers lying next to one another pressed in one operation, and then hardened in the mold.

The ram has several penetrating into the individual molds, and stamping parts compressing the material.

According to a further advantageous embodiment of the present Invention, the mold is provided with a vibrator. The same can preferably come to act on a boundary surface of the mold.

The # vibrator expediently consists of an eccentric driven one Device, and it can vibrate at frequencies of 1 - looo Hz, preferably of 5 - loo Hz. Electromagnetic has also proven to be particularly advantageous powered vibrator proved.

As the filling of the mold especially when several molds to are combined in a compression mold package, usually takes a long time to complete, is according to a particularly advantageous embodiment of the present invention a dosing vessel is provided, the volume of which is exactly the same as the volume to be filled Corresponds to compression molds and in which the material to be formed from the mixing device is filled and then transferred into the molds.

For this purpose, the dosing vessel is provided with a removable base, the when the filled dosing vessel on the filling openings of the to be filled Compression molds is arranged, is pulled away, so that all belonging to a compression mold package Compression molding at the same time with the precisely measured amount of the material from mineral Ingredients and curable organic binders.

The dosing vessel can be filled according to the number of Compression molds according to another embodiment of the present invention be provided with partition walls, so that each mold is special for you measured volume of the material to be molded is obtained.

In this way, even with a die pack with a larger one Number of molds always a simultaneous filling and thus also a uniform one Hardening of the artificial stones or artificial stone slabs achieved.

According to a further advantageous embodiment of the present Invention is the mold or the molds are on their, the press ram opposite Boundary surface with a molding to create a desired edge profile of the pressed part provided.

Such an edge profile can be used, for example, as part of a groove and spring connection, i.e. designed as a groove strip or as a spring strip, consequently to form the edge of the artificial stone slab as a tongue profile or as a groove profile.

Advantageously, is still between the ram and the material to be pressed a further molding to produce the second desired Edge profile provided.

In this way, the manufactured artificial stone slabs can later be removed easy to connect to artificial stone walls.

According to a further advantageous embodiment of the invention Device are the two narrow lateral boundary surfaces of the mold also designed as moldings.

In this way, the artificial stone slab can be used on all sides with the appropriate Profiles should be provided that their connection with neighboring artificial stone plates is essential relieved.

The mold itself can be opened in the usual way to to remove the formed and hardened artificial stone or the artificial stone slab.

Based on what is described below and shown in the drawings Embodiment is the inventive method and the device for Implementation of this procedure explained in more detail.

Example: The plant for the production of artificial stones and artificial stone slabs With reference to Figures 1 and 2, comprises: A sand silo 1 from which the sand is filled into a mixer 3 via an automatic scale 2.

The mixer is expediently mounted on a work platform, and off a storage vessel for the hardenable resin 4 is via a corresponding metering device 5 the resin mixed with the sand filled in the mixer 3.

Either a pump can be used for metering the hardenable resin are used, which are controlled by a timer, certain time intervals runs and conveys a defined amount of resin into the mixer.

Instead of such a metering pump, a metering vessel can also be used which is filled and, if necessary, emptied into the mixer in one go.

This latter procedure appears cumbersome, but it is This is preferable because the batch production of the mixture is always one needs a certain amount of time, so that in the meantime the amount of resin for the next batch can already be measured, and is therefore immediately available when required. A further additional metering device can - if necessary - the mix another dye can be added.

After filling the mixer with sand and hardenable resin and if necessary. the dye, the mixing process begins. The mixing time depends on the type of resin and dye used, and it still depends on the amount of ingredients put into the mixer. The exact mixing time until a uniform distribution can be achieved experimentally very easily determine.

The mixed material is filled into a dosing carriage 6 by the mixer, which is dimensioned so that it takes just the amount of mix required to fill the summarized in a compression mold package Compression molding is necessary.

The dosing carriage 6 is expediently on rails to the mold or to Die package driven. The rails are at a height of approx. 2 m, so that the press can be filled directly from above.

When the dosing carriage is just above the mold, its bottom closures opened so that the # sand-resin mixture runs into the mold 7.

The same becomes during and after the filling of the action a vibrator 8 exposed. Each mold of the compression mold package is then with one correspondingly formed molding 9 covered, and then the ram 10 brought into action, the one shown in the accompanying drawing Embodiment is divided into three head pieces 11, 12, 13, which in the upper Openings of the compression molds 7 protrude and compress the material to be cured.

The plates are hardened by heat in approx. 20 minutes.

This heat is supplied to the press by hot bl, which is in a heating system and heated in the through channels provided in the press mold wall 14 circulates.

After completion of the heating process, which lasts about 20 minutes, the The pressure in the hydraulic cylinder is reduced, the upper mold strip is removed and that of the press mold package summarized molds opened, and the molded and hardened plates removed and stored vertically with the necessary space to cool down.

The die pack is then closed again, the inside of the The mold and the surface of the molded profiles used therein are with a Release agent sprayed, and then the molds are again made with the mix mineral components and curable organic binders for the manufacture new plates loaded.

The following components are used for the process according to the invention Application: A mineral components: The most diverse substances are used into consideration.

Particularly beneficial results have been achieved with quartz sand, lime sand, ground pumice stone, gravel sand and crushed sand received.

The grain size of the mineral components is expediently between o, o5 and 4 mm. It has proven to be particularly advantageous if the used mineral components within the aforementioned range to 3 - 8 different ones defined grain sizes are limited, if not the full range of Particle sizes are present, but only certain, preferred size ranges.

It varies depending on the type of mineral substances used on the one hand the size range, and then on the other hand the number of those from this size range selected grain sizes.

The following are the most beneficial for preferred mineral ingredients Size range, as well as the number of preferred grain sizes listed: Quartz sand: from 0.05 to 2> o mm in 3 - 6 different grain sizes blast furnace slag: from 0.02 Ground pumice stone up to 1.0 mm in 4 - 7 different grain sizes: from o, 5 up to 4.0 mm in 4 - 7 different grain sizes Gravel sand: grain shape compact, if possible cubic, from o, o5 to 6, o mm in 1 - lo different grain sizes crushed sand: from o, 2 up to 3 mm in 4 - 8 different grain sizes.

B resinous constituents: As binders in the invention Method preferred Phenol-formaldehyde resins or urea-formaldehyde resins or melamine resins are used, with a setting above 50%.

The usual additives are expediently added to these binders, such as hardeners, hardening accelerators etc. added before going with the mineral Proportion to be mixed. The addition of these additives can of course can also be done at the same time as mixing.

In addition to the hardening agents and hardening accelerators, So-called water repellants are also added, which increase the water absorbency of the end product, which is essential for external facades.

The relationship between mineral components on the one hand and organic binders, on the other hand, can vary within wide limits. That Ratio depends largely on the required physical properties.

Higher proportions of binder than 10 parts by weight of binder to 90 Parts by weight of mineral components are usually not required and only lead to an unnecessary increase in the price of the product. Lower proportions than 1.5 parts by weight per 98.5 parts by weight of mineral ingredients are usually due No longer recommended due to the properties achieved.

The physical properties of the according to the method of the invention obtained slabs and artificial stones are as follows when using quartz sand: Volume weight: 1,600 KG / m3 Bending tensile strength: approx. 170 Kp / cm2 2 compressive strength approx. 400 Kp / cm modulus of elasticity: 160,000 Kp / cm2 coefficient of thermal expansion : linear CTE 20-200 ° C, approx. 140 ~ 10 7 / OC according to the method according to the invention obtained artificial stones and artificial stone slabs show a low water absorption capacity, they are not flammable, they have an antiseptic effect and they are suitable for Sawing, dowelling, nailing, screwing and drilling.

They also have a very good sound-absorbing effect.

Due to these properties, they are particularly suitable for building construction, for the production of wall coverings and partitions.

Claims (22)

Claims Process for the production of artificial stones and plates from mineral Ingredients and curable organic binders that are mixed, filled in molds, pressed and cured with the addition of heat, d a -d u r c h g e k e It should be noted that the mixture filled into the molds preferably before the Pressure is subjected to a vibration treatment, and during or after is cured by pressing at an elevated temperature. 2.) The method according to claim 1, d a d u r c h g e k e n n -z e i c It should be noted that the vibration treatment of the mixture was carried out for 1 to 600 seconds and pressing is carried out at a pressure of 0.5 - 50 kp / cm2. 3.) The method of claim 1 or 2, d a d u r c h g e -k e n n z e i c h e t that the mixture is at a temperature in the range of 150-300 ° C 10 to 30 minutes, preferably 20 minutes. 4.) The method according to any one of claims 1-3, d a d u r c h g e k It is noted that the mixture was heated to the curing temperature in a The mold (7) was filled, subjected to the vibration treatment and the pressure treatment and is cured by staying in the mold. 5.) The method according to any one of claims 1-4, d a d u r c h g e k It is noted that the mold (7) before filling the mixture with a Release agent is coated. 6.) The method according to any one of claims 1-5, d a d u r c h g e does not indicate that the mixed material is filled into a dosing vessel (.6) and then poured into the mold (7) in one pour, the vibration and pressure treatment is subjected and cured. 7.) Device for performing the method according to the claims 1 - 6, consisting of a dosing and mixing device, a press mold with a press ram and a heating device, d u r c h e k e n n n z e i c h -n e t that the The die (7) is arranged in relation to the ram (lo) so that the ram comes into effect on a small boundary surface of the compact. 8.) Device according to claim 7, d a d u r c h g e k e n n -z e i c h n e t that the ram (lo) in the vertical direction on the compact to Action is coming. 9.) Device according to claim 7, d a d u r c h g e k e n n -z e i c h n e t that the ram (10) in the horizontal direction on the compact to Action is coming. 10.) Device according to one of claims 7-9, d a d u r c h g e it is not possible to say that in or on the wall of the compression mold (7) feed-through lines (14) are provided for the heating medium. 11.) Device according to claim lo, d a d u r c h g e -k e n n z e i c h n e t that the heating medium consists of heated bl, and that a heating and Conveyor device for the O1 is provided. 12.) Device according to claim 11, d a d u r c h g e k e n n -z e i c h n e t that a thermostat is provided in the circuit of the heating medium. 13.) Device according to claim 7-12, d a d u r c h g e -k e n n z e i c h n e t that two or more compression molds (7) are combined to form a Pr # ßfqr # npaket are. 14.) Device for performing the method according to claim 1 or 2, preferably according to claim 7-13, from a metering and mixing device, a Mold and a heating device that a vibrator (8) is provided which acts on the mold (7). 15.) Device according to claim 14, d a d u r c h g e -k e n n z e i c h n e t that the vibrator (8) on a boundary surface of the mold (7) to Action is coming. 16.) Device according to claim 14 or claim Ij, d a -d u r c h it is noted that the vibrator (8) consists of a. driven by eccentric Arrangement exists. 17.) Device according to claim 14 or claim 15, d a -d u r c h it is noted that the vibrator (8) consists of an electromagnetically driven Arrangement exists. 18.) Device according to one of claims 7-17, d a d u r c h g e k e n n n n e i c h n e t that between the mixer (3) and the mold (7) there is a dosing vessel (6) is provided, which is a loading of the mold (s) (7) in one cast enables. 19.) Device according to one or more of claims 7-18, d a d u r c h g e k e n n n z e i c h n e t that the press mold (7) on its, the press ram (10) opposite Boundary surface with a molding (15) is provided to produce a desired edge profile of the compact. 20.) Device naph Anapruch 19, -d a d u r c h g e -k e n n z e i c h n e t that between the ram (10) and the material to be pressed a further molding (9) is provided for producing a second desired edge profile is. 21.) Device according to claim 19 and claim 20, d a -d u r c h it is noted that the two profile strips (9, 15) are designed as a groove or Spring profile strips are formed. 22.) Device according to one of claims 19-21, d a -d u r c h it is not noted that the two narrow lateral boundary surfaces the mold (7) are also designed as moldings. L e r s e i t e