EP0245313B1 - Process for manufacturing parts having a flat surface from hard gem-stone material - Google Patents

Process for manufacturing parts having a flat surface from hard gem-stone material Download PDF

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Publication number
EP0245313B1
EP0245313B1 EP86906255A EP86906255A EP0245313B1 EP 0245313 B1 EP0245313 B1 EP 0245313B1 EP 86906255 A EP86906255 A EP 86906255A EP 86906255 A EP86906255 A EP 86906255A EP 0245313 B1 EP0245313 B1 EP 0245313B1
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EP
European Patent Office
Prior art keywords
process according
coating
pieces
rod
additional pigment
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EP86906255A
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German (de)
French (fr)
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EP0245313A1 (en
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Victor Alexander Milles
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Individual
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Individual
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B44—DECORATIVE ARTS
    • B44C—PRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
    • B44C3/00—Processes, not specifically provided for elsewhere, for producing ornamental structures
    • B44C3/005—Removing selectively parts of at least the upper layer of a multi-layer article
    • G—PHYSICS
    • G04—HOROLOGY
    • G04B—MECHANICALLY-DRIVEN CLOCKS OR WATCHES; MECHANICAL PARTS OF CLOCKS OR WATCHES IN GENERAL; TIME PIECES USING THE POSITION OF THE SUN, MOON OR STARS
    • G04B37/00—Cases
    • G04B37/22—Materials or processes of manufacturing pocket watch or wrist watch cases
    • G04B37/225—Non-metallic cases
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10S264/00—Plastic and nonmetallic article shaping or treating: processes
    • Y10S264/59—Processes in which a partial cure is involved

Definitions

  • the invention relates to a method for producing parts having a smooth surface from gemstone-like hard material according to the preamble of claim 1.
  • Semi-precious stone-like hard materials for use as a substitute for semi-precious stones and for the production of gem-like products are known, for example, from patent application DE-C-3445189.
  • a binder is mixed with a filler and a basic pigment to give a pasty consistency.
  • the dough is cut into pieces at least once, coated with an additional pigment and then pressed together.
  • this doughy mass is hardened, either as such or after a further processing step such as calendering or other shaping.
  • the surface of the dough is completely covered by the additional pigment because the pieces in which the dough is divided are always coated with the additional pigment.
  • a decorative structure of the finished product is therefore only perceptible after the surface has been removed.
  • a further step is necessary after shaping, e.g. abrasive polishing in order to remove the additional pigment coating from the perceptible surface of the blank and to give this surface the desired texture (e.g. the gloss).
  • Such abrasive polishing is disadvantageous: on the one hand, such a step increases the cost of production, on the other hand, certain shapes, e.g. such shapes, which have recesses and depressions with inner edges, are not polished at all or only with great effort.
  • the polishing accompanied by the removal has a particularly disadvantageous effect on small precision parts such as watch shells: the optimal material density is located near the surface of the blanks on the so-called press skin, and the deeper the surface layer of a blank is removed, the more porous the finished part appears. For such a result, it is often necessary to compact the surface machined by abrasive polishing again by pressing again.
  • the invention is based on the knowledge that the removal of the surface layer to expose the decorative structure of a blank and the creation of a smooth surface of the corresponding finished part can be carried out in two separate steps.
  • One consequence of this finding is that it can be accepted that the removal of the surface layer does not leave a smooth, but rather a matt or even rough surface of the part: in the subsequent step, this matt or rough surface can also be smoothed using methods that: generate no removal.
  • This invention therefore creates a method with which parts made of hard stone-like hard mass, which have a smooth surface, can be economically and continuously manufactured on the assembly line.
  • Fig. 1 it is schematically illustrated how, in a manner known per se (cf. DE-C-3445189), a dough mass 1 in a kneader 2 is divided into pieces several times and kneaded together again, for example with the help of planing and pressing rollers 3.
  • This dough, divided into pieces 4 then emerges from the kneader 2 and enters a coating device 5.
  • the pieces 4 are swirled and coated with an additional pigment 6, which is symbolized by the spiral indication of the additional pigment 6.
  • pieces 7 are obtained which are coated with additional pigment and serve as raw material for the next process step, which is described below.
  • This process can also be applied to granules, whereby a further division of the pieces is of course not necessary.
  • a dough composition of the type described in DE-3445189 which consists of a binder, a filler and a base pigment, can be used as the dough mass 1. It is about play for one of the indicated different dough masses 1a to 1e.
  • the binder is a curable synthetic resin with an inherent color of low color density, which is also tough and has a low tendency to become brittle.
  • the binder is an epoxy two-component resin.
  • This synthetic resin is also selected so that it cures either gradually or slowly enough so that the mass is able to remain in an incompletely cured intermediate state for some time between its doughy consistency at the beginning of the process and its hard nature at the end of the process. In this intermediate state the incomplete. When hardened, the dough is no longer flowable under its own weight, but it is still soft enough for shaping by pressing, embossing, cutting and the like.
  • the filler is, for example, a mineral filler that gives the fully hardened finished part its actual hardness and that can contribute to the base color.
  • a mineral filler that gives the fully hardened finished part its actual hardness and that can contribute to the base color.
  • quartz powder, marble powder, ground silica gel, aluminum oxide etc. can be used, i.e. usually substances with a Mohs hardness of 5 to 8, which corresponds to the hardness of semi-precious stones such as turquoise, agate, onyx, carnelian, etc.
  • the basic pigment serves to achieve the basic color or, if the filler also contributes to the color, to achieve the predominant color.
  • the different dough masses 1a to 1e illustrated in FIG. 1 differ, for example, in color from one another, for example one is black, another is white, and still others simulate the basic colors of lapis, turquoise or rhodonite gemstones and the like.
  • the additional pigment is also selected, which is used to achieve the desired decorative structure or pattern of the finished part to be produced using the method described.
  • the additional pigment can, for example, be white, black or metal-colored and accordingly can consist, for example, of titanium dioxide, graphite, aluminum, copper, brass, bronze and the like in the form of dust, powder, spangles or granules. If necessary, a mixture of pigments can also be used, either a homogeneous mixture of pigments or, to achieve special effects, a non-homogeneous mixture of pigments.
  • FIG. 2 schematically illustrates how pieces 7 of different dough masses or granules coated with additional pigment are introduced into a funnel 8 in each case, in order to get to a metering device 9 from there.
  • Fig. 2 four funnels 8 and four corresponding dosing devices 9 were shown as an example, in which, for example, three different dough masses 1a, 1b and 1c and a granulate Ig are processed.
  • the pieces 10 dispensed by the metering devices 9 and coated with additional pigment are combined again at the outlet of the metering devices 9 in a manner known per se (cf. DE-3445189) by being pressed together and pressed, but not mixed.
  • the pad 13 consists, for example, of a foil made of a plastic such as polvamide, polyethylene, polycarbonate, polyimide and the like.
  • the composite 19 consisting of the covering 17 and its base 13 is thus produced continuously.
  • the additional pigment previously lying on the surface of the pieces 10 now being located in the topping 17 at the grain boundaries 18 resulting from these surfaces there are many possible variations for the decorative structure of the topping 17, the additional pigment previously lying on the surface of the pieces 10 now being located in the topping 17 at the grain boundaries 18 resulting from these surfaces .
  • the upper and lower surfaces of the covering 17 each also form a plane composed of grain boundaries, and in fact the upper and lower surfaces of the covering 17 are also coated with the additional pigment, which of course has the desired decorative structure, i.e. the structural veins and generally the pattern of the finished part to be manufactured are covered.
  • the desired decorative structure i.e. the structural veins and generally the pattern of the finished part to be manufactured are covered.
  • the composite 19 consisting of the covering 17 and its base 13 is continuously fed to a processing station 20 in a next process step, which is illustrated schematically in FIG. 3.
  • the topping 17 is continuously subjected to a first, incomplete curing, in such a way that the incompletely hardened dough mass of the topping 17 is no longer flowable under its own weight if it was described below as it continued to advance bene second processing station 23 reached. If the incompletely hardened dough mass corresponds to the previous definition, it shows approximately that. correct consistency to be subjected to the process steps described below.
  • the desired incomplete curing can take place, for example, by thermal treatment of the composite 19 in the processing station 20.
  • an infrared radiator 22 can heat up the upper and lower surfaces of the composite 19 in the processing station 20.
  • the upper and lower surfaces of the composite 19 can also be blown with warm air or sprayed with hot water.
  • the second processing station 23 is arranged at such a distance from the first processing station 20 that, depending on the kinetics of the curing process and the advancing speed of the composite 19, approximately that degree of curing is achieved at which the incompletely cured dough mass of the topping 17 is barely below its own Weight flow is when the composite 19 reaches the second processing station 23 with its continuous advancement.
  • the top 24 of the composite 19 is processed in such a way that the surface layer of the covering 17 containing the additional pigment is removed.
  • the surface layer of the covering 17 containing the additional pigment can be removed by successive process steps of loosening, washing and drying the upper side 24 of the composite 19.
  • the composite 19 in its continuous passage through the processing station 23, first passes through a solution point 26 where the upper side 24 of the composite 19 is sprayed with a solvent, then a washing point 27 where the solvent is sprayed from the upper side 24 of the composite 19 is washed away with a detergent and thereby the action of the solvent is ended, and finally a drying point 28 where the top 24 of the composite 19 is blown free of the detergent by a gas stream.
  • the action of the solvent is dimensioned such that the top 25 of the composite 19 at the exit of the second processing station 23 from the surface layer containing the additional pigment of the covering 17 is exempt, so that the desired decorative structure, ie the structural veins and generally the pattern of the finished part to be produced has become visible on the top 24 of the covering 17.
  • the solvent is therefore chosen so that it is able to dissolve the incompletely hardened synthetic resin in the covering 17.
  • acetone, trichlorethylene and the like can be used as the solvent.
  • a liquid that is not a (or at least not a good) solvent for the incompletely hardened synthetic resin can be used as the detergent, but is miscible with the solvent.
  • the dilution and washing away of the solvent by the detergent thus ends the dissolution of the surface layer of the covering 17.
  • it is advisable to use a cold detergent If acetone is used as the solvent, water and especially cold water can be used as the detergent. If trichlorethylene is used as the solvent, alcohol, petrol or benzene can be used as the detergent and in particular as the cold detergent.
  • Air in particular dry air and, if necessary, cold air can be used as the drying gas for blowing away the detergent.
  • the upper side 24 of the composite 19 can be machined by mechanical removal in order to remove the surface layer of the covering 17 containing additional pigment.
  • the top 24 of the covering 17 can be sprayed with a dispersed abrasive.
  • This abrasive agent can be a powder suspended in a liquid, for example a suspension of emery in water, or also a powder atomized in a gas, for example a suspension of emery in an air stream.
  • the mechanical Removing the additional pigment-containing surface layer of the covering 17 with an adhesive tape or by planing, grinding or such machining.
  • the desired decorative structure i.e. the structural veins and generally the pattern of the prefabricated part to be made visible on the upper side 24, however, this upper side 24 has not yet been given a decorative mirror finish, but has become matt or even rough due to the removal of the surface layer. Therefore, the composite 19 exiting the second processing station 23 is continuously fed to a third processing station 29, where the top 24 of the composite 19 is smoothed as described below to give it the final desired decorative appearance.
  • this process step of smoothing the top 24 of the composite 19 is independent of both the process step of shaping required to form the desired molded parts from the dough mass of the topping 17 and the process step of curing the dough mass of the topping 17 or the molded parts formed therefrom to a hard mass.
  • the third processing station 29 is therefore designed as a hot and molding press, for example as a corresponding stamp press.
  • the continuously supplied composite 19 is pressed therein between a heated die 30 and a heated punch 31, the punch 31 having mirror-smooth surfaces 32 which give the top 33 of the molded part 34 which has now been created from the composite 19 the desired smooth appearance.
  • the dough is heated, which starts the hardening of the binder again until the dough is converted into a hard mass.
  • the temperature of the die and the punch is selected depending on the temperature and the degree of hardening of the supplied material, the residence time of the molded part in the press and other parameters known per se, such that the finished parts may have a suitable waiting or storage time achieve the desired degree of hardness.
  • this hot and compression molding does not require a particularly high pressing pressure, because the press processes a material that has not yet been fully hardened, which is therefore still quite soft and offers little resistance to the press. It is also advantageous that there is no significant amount of pressed or stamping waste, which helps to keep the production costs low.
  • the molded parts can be given such a shape that they can be easily separated from one another. For example, they can have weak points 35 along which they can be cut, punched or broken off from the hardened composite 19, which is indicated schematically in FIG. 3 by the punching device 36. If deburring is necessary, it can be carried out in the same step.
  • the base 13 will adhere to it inseparably after the first, incomplete curing of the dough mass of the topping 17. This is even an advantage if the underside of the composite 19 or the molded part 34 is used, for example, as an adhesive surface when the finished part is used or is processed in some other way, since this further processing can be facilitated by a suitable choice of the material of the base 13.
  • the base After being shaped by the die 30 of the press, the base forms a generally acceptable underside of the finished part, for example a smooth plastic layer on the underside of a finished part, such as a shell or a dial for a watch. Since the base 13 is generally softer than the hardened covering 17 or as the molding material [34], it is easily cut up when the molded parts are separated from one another and also separated with the molded parts.
  • the prefabricated parts produced in this way have a gem-like structure, which enables a wide range of uses for decorative purposes, both as small parts, for example shells and dials of watches, and as flat parts, for example tiles, tiles, etc.
  • FIG. 4 A variant of the described method is illustrated schematically in FIG. 4.
  • the essence of this variant is that the surface layer of the covering 17 containing additional pigment is removed in the presence of ultrasound.
  • the device shown schematically in FIG. 4 has the device already described in connection with FIG. 2, the same reference numerals being used for equivalent parts.
  • the molded parts 37 are formed between the pair of rollers 38, 39 even before the surface layer of the covering 17 containing the additional pigment is removed.
  • the heating for incomplete curing of the dough mass of the topping 17 fails to the extent that in this example it is assumed that the curing already starts in the metering device 9 and that the suitable degree of curing is achieved at room temperature or at the operating temperature of the metering device 9 when the molded parts 37 reach the roller pair 38, 39.
  • the molded parts 37 are still held together by the not yet separated base 13 and immersed in a bath 40 and carried out.
  • This bath 40 contains a suspension of an abrasive in a liquid, for example a suspension of emery in water.
  • An ultrasound generator 41 is immersed in this bath 40 and in this liquid, which whirls up the suspended particles and thus causes abrasion of the surface pigment-containing surface layer of the individual molded parts 37.
  • This is followed, as in FIG. 3, by the smoothing and hardening of the surface of the molded parts 37, here with the aid of a hot press with a pair of rollers 42, 43, and finally in the device 44, the punching out and, if necessary, the deburring and the cutting of the base 13.
  • the device shown schematically in FIG. 5 is used to carry out a variant of the method.
  • this device according to FIG. 5 which are equivalent to certain parts of the devices already described, the same reference numerals are used as in FIGS. 2 to 4.
  • a profiled press strand 17 is formed. 5 this is done with the aid of rollers such as 11 and 12, but other devices known per se can also be used for pressing out the strand 17, for example a piston press and the like.
  • the surface to be used, which has no coating with additional pigment, is formed by cutting the profiled extrusion 17.
  • the smoothing of the surface 46a, 46b to be used of the partial profiles 24a, 24b can be carried out according to the same principle as described in connection with FIG. 4 in the same processing step as the shaping for the formation of separable molded parts from at least one of the partial profiles 24a , 24b.
  • the hardening of the molded parts can also be completed in the same processing step as the shaping.
  • the profiled press strand can be cut normally to its direction of advance, so that the press strand is divided into successive pieces.
  • the surface to be used can be smoothed as in the previous processing step in the same way as shaping to form molded parts from the pieces of the press strand.
  • the hardening of the molded parts can also be completed in the same processing step as the shaping.

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Abstract

A paste consisting of pasty or granular material coated with additional pigment and then re-pressed is applied to a support (13) in the form of a pressed strip or covering (17). The strip or covering is subjected to a first, incomplete hardening (20), after which it can no longer flow easily under its own weight. After this, the surface coat containing the additional pigment is removed from a surface (24) which is to be used, and then this surface is smoothed (29, 32) and the hardening of the coating is terminated to produce a hard material (29). The smoothing and completion of the hardening process can be effected in the same processing stage as shaping (29) to produce separable shaped parts (34). The support (13) can be inseparable from the hardened coating (19). The surface layer containing the additional pigment can be removed by mechanical means, solution means or by abrasion by a suspension in liquid or air, if necessary in the presence of ultrasound (40, 41). The strip can also be cut in order to form a surface layer free of additional pigment. The process is applicable for the production of moldings resembling gem-stones.

Description

Die Erfindung betrifft ein Verfahren zur Herstellung von eine glatte Oberfläche aufweisenden Teilen aus schmucksteinähnlicher Hartmasse gemäss dem Oberbegriff des Anspruchs 1.The invention relates to a method for producing parts having a smooth surface from gemstone-like hard material according to the preamble of claim 1.

Halbedelsteinähnliche Hartmassen zur Verwendung als Ersatz von Halbedelsteinen und zur Herstellung von schmucksteinähnliche Produkten sind beispielsweise aus der Patentanmeldung DE-C- 3445189 bekannt. Nach dieser Lehre wird ein Bindemittel mit einem Füllstoff und einem Grund- Pigment zu teigiger Konsistenz vermischt. Dann wird die teigige Masse mindestens einmal in Stücke zerteilt, mit einem Zusatzpigment beschichtet und anschliessend zusammengedrückt. Danach wird diese noch teigige Masse ausgehärtet, und zwar entweder als solche oder nach einem weiteren Verarbeitungsschritt wie beispielsweise Kalandrieren oder sonstiges Formgeben.Semi-precious stone-like hard materials for use as a substitute for semi-precious stones and for the production of gem-like products are known, for example, from patent application DE-C-3445189. According to this teaching, a binder is mixed with a filler and a basic pigment to give a pasty consistency. Then the dough is cut into pieces at least once, coated with an additional pigment and then pressed together. Then this doughy mass is hardened, either as such or after a further processing step such as calendering or other shaping.

Dabei stellt sich der Nachteil ein, dass die Oberfläche der Teigmasse vom Zusatzpigment vollständig überzogen ist, weil die Stücke, in denen die Teigmasse zerteilt wird, stets wieder mit dem Zusatzpigment beschichtet werden. Dies gilt auch für den Fall, bei welchem die Teigmasse in Form eines verarbeitbaren Granulats eingesetzt wird. Eine dekorative Struktur des fertigen Produkts ist daher nur nach Abtragen der Oberfläche wahrnehmbar. Zur Schaffung einer solchen dekorativen, z.B. marmorähnlichen Struktur bei einem geformten fertigen Produkt, z.B. bei einer Uhrenschale oder einem Messergriff, ist nach der Formgebung ein weiterer Schritt nötig, z.B. ein abtragendes Polieren, um den Zusatzpigment-Überzug von der wahrnehmbaren Oberfläche des Rohlings zu entfernen und dieser Oberfläche die gewünschte Beschaffenheit (z.B. den Glanz) zu geben.The disadvantage arises that the surface of the dough is completely covered by the additional pigment because the pieces in which the dough is divided are always coated with the additional pigment. This also applies to the case where the dough is used in the form of a processable granulate. A decorative structure of the finished product is therefore only perceptible after the surface has been removed. To create such a decorative, e.g. marble-like structure in a molded finished product, e.g. with a watch case or a knife handle, a further step is necessary after shaping, e.g. abrasive polishing in order to remove the additional pigment coating from the perceptible surface of the blank and to give this surface the desired texture (e.g. the gloss).

Ein solches abtragendes Polieren ist aber nachteilig: einerseits verteuert ein solcher Schritt die Fertigung, andererseits können gewisse Formen, z.B. solche Formen, die Ausnehmungen und Vertiefungen mit Innenkanten aufweisen, gar nicht oder nur unter sehr grossem Aufwand poliert werden. Zudem wirkt sich das vom Abtragen begleitete Polieren besonders bei kleinen Präzisionsteilen wie Uhrenschalen besonders nachteilig aus: die optimale Materialdichte befindet sich in Nähe der Oberfläche der Rohlinge auf der sogenannten Presshaut, und je tiefer die Oberflächenschicht eines Rohlings abgetragen wird, desto poröser erscheint das Fertigteil. Bef einem derartigen Ergebnis ist es oft nötig, die durch abtragendes Polieren bearbeitete Oberfläche durch erneutes Pressen wieder zu verdichten.Such abrasive polishing is disadvantageous: on the one hand, such a step increases the cost of production, on the other hand, certain shapes, e.g. such shapes, which have recesses and depressions with inner edges, are not polished at all or only with great effort. In addition, the polishing accompanied by the removal has a particularly disadvantageous effect on small precision parts such as watch shells: the optimal material density is located near the surface of the blanks on the so-called press skin, and the deeper the surface layer of a blank is removed, the more porous the finished part appears. For such a result, it is often necessary to compact the surface machined by abrasive polishing again by pressing again.

Zur Vermeidung dieser Nachteile geht die Erfindung von der Erkenntnis aus, dass das Abtragen der Oberflächenschicht zur Freilegung der dekorativen Struktur eines Rohlings und das Erzeugen einer glatten Oberfläche des entsprechenden Fertigteils in zwei separaten Schritten vorgenommen werden können. Eine Konsequenz dieser Erkenntnis ist, dass man es in Kauf nehmen kann, dass das Abtragen der Oberflächenschicht keine glatte, sondern eine matte oder sogar rauhe Oberfläche des Teils hinterlässt: beim nachfolgenden Schritt kann diese matte oder rauhe Oberfläche auch mit solchen Verfahren geglättet werden, die kein Abtragen erzeugen.To avoid these disadvantages, the invention is based on the knowledge that the removal of the surface layer to expose the decorative structure of a blank and the creation of a smooth surface of the corresponding finished part can be carried out in two separate steps. One consequence of this finding is that it can be accepted that the removal of the surface layer does not leave a smooth, but rather a matt or even rough surface of the part: in the subsequent step, this matt or rough surface can also be smoothed using methods that: generate no removal.

Zur Erreichung dieses Resultats ist ein Verfahren der eingangs erwähnten Art gekennzeichnet durch die im Anspruch 1 angegebene Kombination von Verfahrensschritten. Vorteilhafte Weiterbildungen des Verfahrens sowie eine Anwendung desselben ergeben sich aus den abhängigen Ansprüchen.To achieve this result, a method of the type mentioned at the outset is characterized by the combination of method steps specified in claim 1. Advantageous further developments of the method and an application of the same result from the dependent claims.

Diese Erfindung schafft also ein Verfahren, mit welchem Teile aus schmucksteinähnlicher Hartmasse, die eine glatte Oberfläche aufweisen, auf wirtschafliche Weise kontinuierlich am Fliessband gefertigt werden können.This invention therefore creates a method with which parts made of hard stone-like hard mass, which have a smooth surface, can be economically and continuously manufactured on the assembly line.

Die Erfindung wird im nachstehenden unter Bezugnahme auf die Zeichnungen näher beschrieben. Es zeigen:

  • Fig. 1 ein Schema und eine Vorrichtung, anhand von denen die Zubereitung der im erfindungsgemässen Verfahren verwendeten Teigmasse erläutert werden kann,
  • Fig. 2 eine Vorrichtung, anhand von welcher die zur Herstellung eines Belags auf einer Unterlage führenden Verfahrensschritte erläutert werden können,
  • Fig. 3 eine Vorrichtung, anhand von welcher die weiteren Verfahrensschritte des erfindungsgemässen Verfahrens erläutert werden können,
  • Fig. 4 eine Vorrichtung, anhand von welcher eine Variante des erfindungsgemässen Verfahrens, bei welcher Ultraschall verwendet wird, erläutert werden kann, und
  • Fig. 5 eine Vorrichtung, anhand von welcher eine Variante des erfindungsgemässen Verfahrens, bei welcher ein Pressstrang statt eines Belags gebildet wird, erläutert werden kann.
The invention is described below with reference to the drawings. Show it:
  • 1 shows a diagram and a device by means of which the preparation of the dough mass used in the method according to the invention can be explained,
  • 2 shows a device by means of which the process steps leading to the production of a covering on a support can be explained,
  • 3 shows a device by means of which the further method steps of the method according to the invention can be explained,
  • 4 shows a device by means of which a variant of the method according to the invention, in which ultrasound is used, can be explained, and
  • 5 shows a device by means of which a variant of the method according to the invention, in which a press strand is formed instead of a covering, can be explained.

In Fig. 1 wird schematisch veranschaulicht, wie auf an sich bekannte Weise (vgl. DE-C- 3445189) eine Teigmasse 1 in einem Kneter 2 beispielsweise mit Hilfe von Hobel- und Presswalzen 3 mehrmals in Stücke zerteilt und wieder zusammengeknetet wird. Anschliessend tritt diese Teigmasse, in Stücke 4 zerteilt, aus dem Kneter 2 aus und in eine Beschichtungsvorrichtung 5 ein. In dieser Beschichtungsvorrichtung 5 werden die Stücke 4 mit einem Zusatzpigment 6 verwirbelt und beschichtet, was durch die spiralförmige Andeutung des Zusatzpigments 6 symbolisiert wird. Am Schluss dieses Verfahrensschrittes werden Stücke 7 erhalten, die mit Zusatzpigment beschichtet sind und als Rohstoff für den nächsten Verfahrensschritt dienen, welcher nachstehend beschrieben wird. Dieses Verfahren kann auch auf Granulat angewandt werden, wobei sich eine weitere Zerteilung der Stücke natürlich erübrigt.In Fig. 1 it is schematically illustrated how, in a manner known per se (cf. DE-C-3445189), a dough mass 1 in a kneader 2 is divided into pieces several times and kneaded together again, for example with the help of planing and pressing rollers 3. This dough, divided into pieces 4, then emerges from the kneader 2 and enters a coating device 5. In this coating device 5, the pieces 4 are swirled and coated with an additional pigment 6, which is symbolized by the spiral indication of the additional pigment 6. At the end of this process step, pieces 7 are obtained which are coated with additional pigment and serve as raw material for the next process step, which is described below. This process can also be applied to granules, whereby a further division of the pieces is of course not necessary.

Als Teigmasse 1 kann beispielsweise eine teigige Zusammensetzung der in DE-3445189 beschriebenen Art verwendet werden, die aus einem Bindemittel, einem Füllstoff und einem Grund-Pigment besteht. Es handelt sich zum Beispiel um eine der angedeuteten verschiedenen Teigmassen 1a bis 1e.For example, a dough composition of the type described in DE-3445189, which consists of a binder, a filler and a base pigment, can be used as the dough mass 1. It is about play for one of the indicated different dough masses 1a to 1e.

Zur Verwendung im vorliegenden Verfahren ist das Bindemittel ein aushärtbares Kunstsharz mit einer Eigenfarbe von geringer Farbdichte, das zudem zähhaftend ist und eine geringe Neigung zur Versprödung aufweist. Beispielsweise ist das Bindemittel ein Epoxy-Zweikomponentenharz. Dieses Kunstharz ist zudem so gewählt, das seine Aushärtung entweder stufenweise oder langsam genug erfolgt, damit die Masse fähig ist, zwischen ihrer teigigen Konsistenz am Anfang des Verfahrens und ihrer harten Beschaffenheit am Ende des Verfahrens einige Zeit lang in einem unvollständig ausgehärteten Zwischenzustand zu verweilen. In diesem Zwischenzustand der unvollständigen. Aushärtung ist dann die Teigmasse knapp nicht mehr unter dem eigenen Gewicht fliessfähig, sie ist jedoch noch weich genug für eine Formgebung durch Pressen, Prägen, Schneiden und dergleichen.For use in the present process, the binder is a curable synthetic resin with an inherent color of low color density, which is also tough and has a low tendency to become brittle. For example, the binder is an epoxy two-component resin. This synthetic resin is also selected so that it cures either gradually or slowly enough so that the mass is able to remain in an incompletely cured intermediate state for some time between its doughy consistency at the beginning of the process and its hard nature at the end of the process. In this intermediate state the incomplete. When hardened, the dough is no longer flowable under its own weight, but it is still soft enough for shaping by pressing, embossing, cutting and the like.

Der Füllstoff ist beispielsweise ein mineralischer Füllstoff, der dem vollständig ausgehärteten Fertigteil seine eigentliche Härte gibt, und der zur Grundfarbe beitragen kann. Es können zum Beispiel Quarzmehl, Marmorpulver, zerriebenes Kieselgel, Aluminiumoxid usw. verwendet werden, also in der Regel Substanzen mit einer Mohs-Härte von 5 bis 8, was der Härte von Halbedelsteinen wie Türkis, Achat, Onyx, Carneol usw. entspricht.The filler is, for example, a mineral filler that gives the fully hardened finished part its actual hardness and that can contribute to the base color. For example, quartz powder, marble powder, ground silica gel, aluminum oxide etc. can be used, i.e. usually substances with a Mohs hardness of 5 to 8, which corresponds to the hardness of semi-precious stones such as turquoise, agate, onyx, carnelian, etc.

Das Grundpigment dient zur Erzielung der Grundfarbe oder, falls der Füllstoff auch zur Farbe beiträgt, zur Erzielung der überwiegenden Farbe. Es können praktisch alle organischen oder anorganischen Pigmente verwendet werden, die zur Färbung von Kunstharzen üblich sind, wobei die organischen Pigmente in der Regel farbkräftiger sind.The basic pigment serves to achieve the basic color or, if the filler also contributes to the color, to achieve the predominant color. Virtually all organic or inorganic pigments that are customary for coloring synthetic resins can be used, the organic pigments generally having more color.

Die verschiedenen in Fig. 1 veranschaulichten Teigmassen 1a bis 1e unterscheiden sich beispielsweise in der Farbe voneinander, die eine ist beispielsweise schwarz, eine andere ist weiss, noch andere simulieren die Grundfarben von Lapis, Türkis oder Rhodonit-Schmucksteinen und dergleichen.The different dough masses 1a to 1e illustrated in FIG. 1 differ, for example, in color from one another, for example one is black, another is white, and still others simulate the basic colors of lapis, turquoise or rhodonite gemstones and the like.

In Abhängigkeit der gewählten Teigmasse wird auch das Zusatzpigment gewählt, das zur Erzielung der gewünschten dekorativen Struktur oder Musterung des mit dem beschriebenen Verfahren herzustellenden Fertigteils dient. Das Zusatzpigment kann beispielsweise weiss, schwarz, oder metallfarben sein und dementsprechend beispielsweise aus Titandioxid, Graphit, Aluminium, Kupfer, Messing, Bronze und dergleichen in Form von Staub, Pulver, Flitter oder Granulat bestehen. Nach Bedarf kann auch ein Gemisch von Pigmenten eingesetzt werden, und zwar entweder ein homogenes Gemisch von pigmenten oder, zur Erzielung von besonderen Effekten, ein nicht homogenes Gemisch von Pigmenten.Depending on the dough mass selected, the additional pigment is also selected, which is used to achieve the desired decorative structure or pattern of the finished part to be produced using the method described. The additional pigment can, for example, be white, black or metal-colored and accordingly can consist, for example, of titanium dioxide, graphite, aluminum, copper, brass, bronze and the like in the form of dust, powder, spangles or granules. If necessary, a mixture of pigments can also be used, either a homogeneous mixture of pigments or, to achieve special effects, a non-homogeneous mixture of pigments.

In Fig. 2 wird schematisch veranschaulicht, wie mit Zusatzpigment beschichtete Stücke 7 aus verschiedenen Teigmassen oder Granulaten in je einen Trichter 8 eingegeben werden, um von dort zu je einer Dosiervorrichtung 9 zu gelangen. In Fig. 2 wurden als Beispiel vier Trichter 8 und vier entsprechende Dosiervorrichtungen 9 dargestellt, in denen beispielsweise drei verschiedene Teigmassen 1a, 1b und 1c und ein Granulat Ig verarbeitet werden. Die von den Dosiervorrichtungen 9 abgegebenen, mit Zusatzpigment beschichteten Stücke 10 werden am Ausgang der Dosiervorrichtungen 9 auf an sich bekannte Weise (vgl. DE-3445189) wieder durch Zusammendrücken und Verpressen vereinigt, aber nicht vermengt. Dies erfolgt durch kontinuierliches Zuführen der Stücke 10 zu einem Walzenpaar mit Walzen 11 und 12, zwischen denen die Stücke 10 kontinuierlich zu einer Schicht verpresst werden. Gleichzeitig wird eine bandförmige Unterlage 13 von einer Vorratsrolle 14 abgezogen und über eine Leitrolle 15 zur Unterseite 16 der erwähnten Schicht der Teigmasse zugeführt. Auf diese Weise wird die aus den mit Zusatzpigment beschichteten und dann wieder zusammengedrückten Stükken 10 bestehende Teigmasse kontinuierlich in Form eines Belags 17 auf die kontinuierlich vorrückende Unterlage 13 aufgebracht. Die Unterlage 13 besteht beispielsweise aus einer Fölie aus einem Kunststoff wie Polvamid, Polyethylen, Polycarbonat, Polyimid und dergleichen.2 schematically illustrates how pieces 7 of different dough masses or granules coated with additional pigment are introduced into a funnel 8 in each case, in order to get to a metering device 9 from there. In Fig. 2 four funnels 8 and four corresponding dosing devices 9 were shown as an example, in which, for example, three different dough masses 1a, 1b and 1c and a granulate Ig are processed. The pieces 10 dispensed by the metering devices 9 and coated with additional pigment are combined again at the outlet of the metering devices 9 in a manner known per se (cf. DE-3445189) by being pressed together and pressed, but not mixed. This is done by continuously feeding the pieces 10 to a pair of rolls with rolls 11 and 12, between which the pieces 10 are continuously pressed into a layer. At the same time, a band-shaped base 13 is pulled off a supply roll 14 and fed via a guide roll 15 to the underside 16 of the above-mentioned layer of the dough. In this way, the dough mass consisting of the pieces 10 coated with additional pigment and then compressed again is continuously applied in the form of a topping 17 to the continuously advancing base 13. The pad 13 consists, for example, of a foil made of a plastic such as polvamide, polyethylene, polycarbonate, polyimide and the like.

Der aus dem Belag 17 und seiner Unterlage 13 bestehende Verbund 19 wird also kontinuierlich hergestellt.The composite 19 consisting of the covering 17 and its base 13 is thus produced continuously.

In Abhängigkeit der jeweils zudosierten Stückmengen aus den jeweils ausgewählten Teigmassen oder Granulaten ergeben sich viele Variationsmöglichkeiten für die dekorative Struktur des Belags 17, wobei das vorher auf der Oberfläche der Stücke 10 liegende Zusatzpigment sich nun an den aus diesen Oberflächen entstandenen Korngrenzen 18 im Belag 17 befindet. Allerdings bilden auch die obere und die untere Oberfläche des Belags 17 im weiteren Sinne je eine aus Korngrenzen zusammengesetzte Ebene, und tatsächlich sind auch die obere und die untere Oberfläche des Belags 17 mit dem Zusatzpigment beschichtet, was natürlich die gewünschte dekorative Struktur, d.h. die Strukturadern und generell die Musterung des herzustellenden Fertigteils verdeckt. Zur Freilegung der gewünschten dekorativen Struktur ist es also nötig, die im hergestellten Fertigteil sichtbare Oberfläche vom Zusatzpigment zu befreien, was jedoch bei der teigigen Konsistenz des Belags 17 recht schwierig ist, wenn keine weiteren Massnahmen gemäss der vorliegenden Erfindung getroffen werden.Depending on the quantities of the dough or granules selected, there are many possible variations for the decorative structure of the topping 17, the additional pigment previously lying on the surface of the pieces 10 now being located in the topping 17 at the grain boundaries 18 resulting from these surfaces . However, in the broader sense, the upper and lower surfaces of the covering 17 each also form a plane composed of grain boundaries, and in fact the upper and lower surfaces of the covering 17 are also coated with the additional pigment, which of course has the desired decorative structure, i.e. the structural veins and generally the pattern of the finished part to be manufactured are covered. To expose the desired decorative structure, it is therefore necessary to remove the additional pigment from the surface visible in the finished part produced, but this is quite difficult given the pasty consistency of the covering 17 if no further measures are taken in accordance with the present invention.

Zur Freilegung der gewünschten dekorativen Struktur wird der aus dem Belag 17 und seiner Unterlage 13 bestehende Verbund 19 in einem nächsten Verfahrensschritt, der in Fig. 3 schematisch veranschaulicht wird, kontinuierlich einer Verarbeitungsstation 20 zugeführt. Dort wird der Belag 17 kontinuierlich einer ersten, unvollständigen Aushärtung unterzogen, derart, dass die unvollständig ausgehärtete Teigmasse des Belags 17 knapp nicht mehr unter dem eigenen Gewicht fliessfähig ist, wenn sie bei ihrem kontinuierlichen Vorrücken die weiter unten beschriebene zweite Verarbeitungsstation 23 erreicht. Wenn die unvollständig ausgehärtete Teigmasse der vorangehenden Definition entspricht, weist sie etwa die. richtige Konsistenz auf, um den nachfolgend beschriebenen Verfahrensschritten unterzogen zu werden.In order to expose the desired decorative structure, the composite 19 consisting of the covering 17 and its base 13 is continuously fed to a processing station 20 in a next process step, which is illustrated schematically in FIG. 3. There, the topping 17 is continuously subjected to a first, incomplete curing, in such a way that the incompletely hardened dough mass of the topping 17 is no longer flowable under its own weight if it was described below as it continued to advance bene second processing station 23 reached. If the incompletely hardened dough mass corresponds to the previous definition, it shows approximately that. correct consistency to be subjected to the process steps described below.

Die gewünschte unvollständige Aushärtung kann beispielsweise durch thermische Behandlung des Verbunds 19 in der Verarbeitungsstation 20 erfolgen. Wie in Fig. 3 mit den Strahlen 21 angedeutet, kann in der Verarbeitungsstation 20 ein Infrarotstrahler 22 die obere und die untere Oberfläche des Verbunds 19 aufwärmen. Zum gleichen Zweck kann die obere und die untere Oberfläche des Verbunds 19 aber auch mit Warmluft angeblasen oder mit Warmwasser besprüht werden.The desired incomplete curing can take place, for example, by thermal treatment of the composite 19 in the processing station 20. As indicated in FIG. 3 with the rays 21, an infrared radiator 22 can heat up the upper and lower surfaces of the composite 19 in the processing station 20. For the same purpose, the upper and lower surfaces of the composite 19 can also be blown with warm air or sprayed with hot water.

Die zweite Verarbeitungsstation 23 ist in einem solchen Abstand von der ersten Verarbeitungsstation 20 angeordnet, dass in Abhängigkeit der Kinetik des Aushärtungsvorgangs und der Vorrückgeschwindigkeit des Verbunds 19 etwa derjenige Aushärtungsgrad erreicht wird, bei dem die unvollständig ausgehärtete Teigmasse des Belags 17 knapp nicht mehr unter dem eigenen Gewichtfliessfähig ist, wenn der Verbund 19 die zweite Verarbeitungsstation 23 bei seinem kontinuierlichen Vorrücken erreicht.The second processing station 23 is arranged at such a distance from the first processing station 20 that, depending on the kinetics of the curing process and the advancing speed of the composite 19, approximately that degree of curing is achieved at which the incompletely cured dough mass of the topping 17 is barely below its own Weight flow is when the composite 19 reaches the second processing station 23 with its continuous advancement.

In dieser zweiten Verarbeitungsstation 23 wird die Oberseite 24 des Verbunds 19 derart bearbeitet, dass die zusatzpigmenthaltige Oberflächenschicht des Belags 17 entfernt wird.In this second processing station 23, the top 24 of the composite 19 is processed in such a way that the surface layer of the covering 17 containing the additional pigment is removed.

Wie in Fig. 3 mit der Besprühung bei 25 angedeutet, kann das Entfernen der zusatzpigmenthaltigen Oberflächenschicht des Belags 17 durch aufeinanderfolgende Verfahrensschritte des Lösens, Waschens und Trocknens der Oberseite 24 des Verbunds 19 erfolgen. Zu diesem Zweck durchläuft der Verbund 19 bei seinem kontinuierlichen Durchgang durch die Verarbeitungsstation 23 zunächst eine Lösungsstelle 26, wo die Oberseite 24 des Verbunds 19 mit einem Lösungsmittel besprüht wird, danach eine Waschstelle 27, wo das Lösungsmittel von der Oberseite 24 des Verbunds 19 durch Besprühen mit einem Waschmittel weggespült wird und dadurch die Einwirkung des Lösungsmittels beendet wird, und schliesslich eine Trocknungsstelle 28, wo die Oberseite 24 des Verbunds 19 durch einen Gasstrom vom Waschmittel freigeblasen wird.As indicated in FIG. 3 with the spraying at 25, the surface layer of the covering 17 containing the additional pigment can be removed by successive process steps of loosening, washing and drying the upper side 24 of the composite 19. For this purpose, the composite 19, in its continuous passage through the processing station 23, first passes through a solution point 26 where the upper side 24 of the composite 19 is sprayed with a solvent, then a washing point 27 where the solvent is sprayed from the upper side 24 of the composite 19 is washed away with a detergent and thereby the action of the solvent is ended, and finally a drying point 28 where the top 24 of the composite 19 is blown free of the detergent by a gas stream.

Dabei wird, durch geeignete Wahl des Lösungsmittels unter Berücksichtigung der Temperatur an der Oberseite 24 des Belags 17 und der Temperatur des Lösungsmittels selbst, die Einwirkung des Lösungsmittels so bemessen, dass die Oberseite 25 des Verbunds 19 am Ausgang der zweiten Verarbeitungsstation 23 von der zusatzpigmenthaltigen Oberflächenschicht des Belags 17 befreit ist, so dass die gewünschte dekorative Struktur, d.h. die Strukturadern und generell die Musterung des herzustellenden Fertigteils, an der Oberseite 24 des Belags 17 sichtbar geworden ist. Das Lösungsmittel wird also so gewählt, dass es den unvollständig ausgehärteten Kunstharz im Belag 17 zu lösen vermag. Als Lösungsmittel können beispielsweise Aceton, Trichlorethylen und dergleichen verwendet werden. Es empfiehli sich, das Lösungsmittel kalt einzusetzen, weil die Abkühlung der zusatzpigmenthaltigen Oberflächenschicht des Belags 17 durch das Lösungsmittel sowohl ihre Auflösung als auch ihre Aushärtung verlangsamt, was mehr Zeit zur Bearbeitung der Oberflächenschicht des Belags 17 zur Verfügung lässt und somit die Konstruktion der zur Ausführung des Verfahrens bestimmten Maschine erleichtert.By appropriate selection of the solvent, taking into account the temperature on the top 24 of the coating 17 and the temperature of the solvent itself, the action of the solvent is dimensioned such that the top 25 of the composite 19 at the exit of the second processing station 23 from the surface layer containing the additional pigment of the covering 17 is exempt, so that the desired decorative structure, ie the structural veins and generally the pattern of the finished part to be produced has become visible on the top 24 of the covering 17. The solvent is therefore chosen so that it is able to dissolve the incompletely hardened synthetic resin in the covering 17. For example, acetone, trichlorethylene and the like can be used as the solvent. It is advisable to use the solvent cold, because the cooling of the surface layer of the coating 17 containing the additional pigment by the solvent slows down both its dissolution and its hardening, which leaves more time for processing the surface layer of the coating 17 and thus the construction of the construction machine facilitated by the process.

Als Waschmittel kann eine Flüssigkeit verwendet werden, die kein (oder zumindest kein gutes) Lösungsmittel für den unvollständig ausgehärteten Kunstharz ist, jedoch mit dem Lösungsmittel mischbar ist. Die Verdünnung und Wegspülung des Lösungsmittels durch das Waschmittel beendet also das Auflösen der Oberflächenschicht des Belags 17. Aus gleichen Gründen wie beim Lösungsmittel empfiehlt es sich, ein kaltes Waschmittel einzusetzen. Wenn als Lösungsmittel Aceton verwendet wird, kann als Waschmittel Wasser und insbesondere kaltes Wasser verwendetwerden. Wenn als Lösungsmittel Trichlorethylen verwendet wird, kann als Waschmittel und insbesondere als kaltes Waschmittel Alkohol, Benzin oder Benzol verwendet werden.A liquid that is not a (or at least not a good) solvent for the incompletely hardened synthetic resin can be used as the detergent, but is miscible with the solvent. The dilution and washing away of the solvent by the detergent thus ends the dissolution of the surface layer of the covering 17. For the same reasons as for the solvent, it is advisable to use a cold detergent. If acetone is used as the solvent, water and especially cold water can be used as the detergent. If trichlorethylene is used as the solvent, alcohol, petrol or benzene can be used as the detergent and in particular as the cold detergent.

Als Trocknungsgas zum Wegblasen des Waschmittels kann Luft, insbesondere trockene Luft und bei Bedarf kalte Luft verwendet werden.Air, in particular dry air and, if necessary, cold air can be used as the drying gas for blowing away the detergent.

In einer Anzahl von nicht dargestellten Varianten der zweiten Verarbeitungsstation 23 kann die Oberseite 24 des Verbunds 19 durch mechanisches Abtragen bearbeitet werden, um die zusatzpigmenthaltige Oberflächenschicht des Belags 17 zu entfernen. In einer dieser Varianten kann die Oberseite 24 des Belags 17 mit einem dispergierten abrasiven Mittel besprüht werden. Dieses abrasive Mittel kann ein in einer Flüssigkeit suspendiertes Pulver sein, beispielsweise eine Suspension von Schmirgel in Wasser, oder auch ein in einem Gas zerstäubtes Pulver, beispielsweise eine Suspension von Schmirgel in einem Luftstrom. In einer anderen Variante kann das mechanische. Abtragen der zusatzpigmenthaltigen Oberflächenschicht des Belags 17 mit einem Klebeband oder durch Hobeln, Abschleifen oder derartiger maschineller Bearbeitung erfolgen.In a number of variants, not shown, of the second processing station 23, the upper side 24 of the composite 19 can be machined by mechanical removal in order to remove the surface layer of the covering 17 containing additional pigment. In one of these variants, the top 24 of the covering 17 can be sprayed with a dispersed abrasive. This abrasive agent can be a powder suspended in a liquid, for example a suspension of emery in water, or also a powder atomized in a gas, for example a suspension of emery in an air stream. In another variant, the mechanical. Removing the additional pigment-containing surface layer of the covering 17 with an adhesive tape or by planing, grinding or such machining.

Nach der vorangehend beschriebenen Bearbeitung der Oberseite, 24 des Verbunds 19 beim Durchlauf durch die zweite Verarbeitungsstation 23 ist zwar die gewünschte dekorative Struktur, d.h. die Strukturadern und generell die Musterung des herzustellenden Fertigteils, an der Oberseite 24 sichtbar geworden, diese Oberseite 24 ist jedoch noch nicht dekorativ spiegelglatt, sondern wegen des Abtragens der Oberflächenschicht matt oder sogar rauh geworden. Daher wird der aus der zweiten Verarbeitungsstation 23 austretende Verbund 19 kontinuierlich einer dritten Verarbeitungsstation 29 zugeführt, wo die Oberseite 24 des Verbunds 19 wie nachstehend beschrieben geglättet wird, um ihr das endgültig gewünschte dekorative Aussehen zu verleihen.After the above-described processing of the top, 24 of the composite 19 as it passes through the second processing station 23, the desired decorative structure, i.e. the structural veins and generally the pattern of the prefabricated part to be made visible on the upper side 24, however, this upper side 24 has not yet been given a decorative mirror finish, but has become matt or even rough due to the removal of the surface layer. Therefore, the composite 19 exiting the second processing station 23 is continuously fed to a third processing station 29, where the top 24 of the composite 19 is smoothed as described below to give it the final desired decorative appearance.

Grundsätzlich ist dieser Verfahrensschritt des Glättens der Oberseite 24 des Verbunds 19 unabhängig sowohl vom noch erforderlichen Verfahrensschritt der Formgebung zur Bildung der gewünschten Formteile aus der Teigmasse des Belags 17 wie auch vom noch erforderlichen Verfahrensschritt der Aushärtung der Teigmasse des Belags 17 bzw. der daraus geformten Formteile zu einer Hartmasse. Es ist jedoch vorteilhaft, die Verfahrensschritte des Glättens, der Formgebung und der Aushärtung in einem Zuge durchzuführen, wie es beispielsweise in Fig. 3 veranschaulicht wird. Daher ist die dritte Verarbeitungsstation 29 als Heiss- und Formpresse, beispielsweise als entsprechende Stempelpresse ausgebildet. Der kontinuierlich zugeführte Verbund 19 wird darin zwischen einer geheizten Matrize 30 und einem geheizten Stempel 31 gepresst, wobei der Stempel 31 spiegelglatte Flächen 32 aufweist, die der Oberseite 33 des nun aus dem Verbund 19 entstandenen Formteils 34 das gewünschte glatte Aussehen verleihen. Gleichzeitig wird die Teigmasse erhitzt, was die Aushärtung des Bindemittels wieder in Gang setzt, bis die Teigmasse in eine Hartmasse umwandelt ist. Selbstverständlich wird die Temperatur der Matrize und des Stempels in Abhängigkeit der Temperatur und des bereits erreichten Aushärtungsgrades des zugeführten Pressguts, der Verweilzeit des Formteils in der Presse sowie anderer an sich bekannter Parameter derart gewählt, dass die Fertigteile gegebenenfalls nach einer geeigneten Warte- oder Lagerzeit den gewünschten Härtegrad erreichen.Basically, this process step of smoothing the top 24 of the composite 19 is independent of both the process step of shaping required to form the desired molded parts from the dough mass of the topping 17 and the process step of curing the dough mass of the topping 17 or the molded parts formed therefrom to a hard mass. However, it is advantageous to carry out the process steps of smoothing, shaping and curing in one go, as is illustrated, for example, in FIG. 3. The third processing station 29 is therefore designed as a hot and molding press, for example as a corresponding stamp press. The continuously supplied composite 19 is pressed therein between a heated die 30 and a heated punch 31, the punch 31 having mirror-smooth surfaces 32 which give the top 33 of the molded part 34 which has now been created from the composite 19 the desired smooth appearance. At the same time, the dough is heated, which starts the hardening of the binder again until the dough is converted into a hard mass. Of course, the temperature of the die and the punch is selected depending on the temperature and the degree of hardening of the supplied material, the residence time of the molded part in the press and other parameters known per se, such that the finished parts may have a suitable waiting or storage time achieve the desired degree of hardness.

Vorteilhaft ist unter anderen, dass bei diesem Heiss- und Formpressen kein besonders hoher Pressdruck nötig ist, weil die Presse ein noch unvollständig ausgehärtetes Material verarbeitet, das also noch ziemlich weich ist und der Presse nur einen geringen Widerstand leistet. Vorteilhaft ist auch, dass keine nennenswerte Menge Press-oder Stanzabfall anfällt, was beiträgt, die Herstellungskosten niedrig zu halten.It is advantageous, among other things, that this hot and compression molding does not require a particularly high pressing pressure, because the press processes a material that has not yet been fully hardened, which is therefore still quite soft and offers little resistance to the press. It is also advantageous that there is no significant amount of pressed or stamping waste, which helps to keep the production costs low.

Den Formteilen kann eine solche Form gegeben werden, dass sie voneinander leicht trennbar sind. Sie können beispielsweise Schwachstellen 35 aufweisen, längs denen sie vom ausgehärteten Verbund 19 abgeschnitten, abgestanzt oder abgebrochen werden können, was in Fig. 3 schematisch mit der Stanzvorrichtung 36 angedeutet ist. Sofern ein Entgraten nötig ist, kann es im gleichen Zuge ausgeführt werden.The molded parts can be given such a shape that they can be easily separated from one another. For example, they can have weak points 35 along which they can be cut, punched or broken off from the hardened composite 19, which is indicated schematically in FIG. 3 by the punching device 36. If deburring is necessary, it can be carried out in the same step.

In der Regel wird die Unterlage 13 bereits nach der ersten, unvollständigen Aushärtung der Teigmasse des Belags 17 daran untrennbar haften. Dies ist sogar ein Vorteil, wenn die Unterseite des Verbunds 19 bzw. des Formteils 34 bei der Verwendung des Fertigteils beispielsweise als Klebefläche dient oder sonstwie weiterverarbeitet wird, da man diese Weiterverabeitung durch eine geeignete Wahl des Materials der Unterlage 13 erleichtern kann. Die Unterlage bildet nach der Formgebung durch die Matrize 30 der Presse sowieso eine meist akzeptable Unterseite des Fertigteils, beispielsweise eine glatte Kunststoffschicht auf der Unterseite eines Fertigteils wie eine Schale oder ein Ziffernblatt für eine Uhr. Da die Unterlage 13 in der Regel weicher ist als der ausgehärtete Belag 17 bzw. als das Fqrmtei[ 34, wird sie beim Trennen der Formteile voneinander problemlos zerteilt und mit den Formteilen mitgetrennt.As a rule, the base 13 will adhere to it inseparably after the first, incomplete curing of the dough mass of the topping 17. This is even an advantage if the underside of the composite 19 or the molded part 34 is used, for example, as an adhesive surface when the finished part is used or is processed in some other way, since this further processing can be facilitated by a suitable choice of the material of the base 13. After being shaped by the die 30 of the press, the base forms a generally acceptable underside of the finished part, for example a smooth plastic layer on the underside of a finished part, such as a shell or a dial for a watch. Since the base 13 is generally softer than the hardened covering 17 or as the molding material [34], it is easily cut up when the molded parts are separated from one another and also separated with the molded parts.

Die auf solche Weise hergestellten Fertigteile weisen eine schmucksteinähnliche Strukturierung auf, die eine vielfältige Verwendung zu Dekorationszwecken ermöglicht, und zwar sowohl als Kleinteile, beispielsweise Schalen und Zifferblätter von Uhren, wie auch als flächige Teile, beispielsweise Fliesen, Kacheln usw.The prefabricated parts produced in this way have a gem-like structure, which enables a wide range of uses for decorative purposes, both as small parts, for example shells and dials of watches, and as flat parts, for example tiles, tiles, etc.

Eine Variante des beschriebenen Verfahrens ist in Fig. 4 schematisch veranschaulicht. Das wesentliche an dieser Variante ist, dass die zusatzpigmenthaltige Oberflächenschicht des Belags 17 in Gegenwart von Ultraschall entfernt wird.A variant of the described method is illustrated schematically in FIG. 4. The essence of this variant is that the surface layer of the covering 17 containing additional pigment is removed in the presence of ultrasound.

Die in Fig. 4 schematisch dargestellte Vorrichtung weist die bereits im Zusammenhang mit Fig. 2 beschriebene Vorrichtung auf, wobei für äquivalente Teile die gleichen Bezugszeichen verwendet werden. Als Beispiel einer Variante werden hier die Formteile 37 zwischen dem Walzenpaar38, 39 bereits vor dem Entfernen der zusatzpigmenthaltigen Oberflächenschicht des Belags 17 gebildet. Das Heizen zur unvollständigen Aushärtung der Teigmasse des Belags 17 fällt insofern aus, als in diesem Beispiel angenommen wird, dass die Aushärtung bereits in der Dosiervorrichtung 9 einsetzt und dass bei Raumtemperatur oder bei der Betriebstemperatur der Dosiervorrichtung 9 der geeignete Aushärtungsgrad erreicht wird, wenn die Formteile 37 das Walzenpaar 38, 39 erreichen. Die Formteile 37 werden noch durch die noch nicht zertrennte Unterlage 13 zusammengehalten und in ein Bad 40 getaucht und durchgeführt. Dieses Bad 40 enthält eine Suspension eines abrasiven Mittels in einer Flüssigkeit, beispielsweise eine Suspension von Schmirgel in Wasser. In dieses Bad 40 und in diese Flüssigkeit taucht ein Ultraschallgenerator 41 ein, der die suspendierten Teilchen aufwirbelt und somit einen Abrieb der zusatzpigmenthaltigen Oberflächenschicht der einzelnen Formteile 37 verursacht. Danach folgt wie in Fig. 3 das Glätten und das Aushärten der Oberfläche der Formteile 37, hier mit Hilfe einer Heisspresse mit einem Walzenpaar 42, 43, und schliesslich inderVorrichtung 44 das Ausstanzen und gegebenenfalls das Entgraten sowie das Zertrennen der Unterlage 13.The device shown schematically in FIG. 4 has the device already described in connection with FIG. 2, the same reference numerals being used for equivalent parts. As an example of a variant, the molded parts 37 are formed between the pair of rollers 38, 39 even before the surface layer of the covering 17 containing the additional pigment is removed. The heating for incomplete curing of the dough mass of the topping 17 fails to the extent that in this example it is assumed that the curing already starts in the metering device 9 and that the suitable degree of curing is achieved at room temperature or at the operating temperature of the metering device 9 when the molded parts 37 reach the roller pair 38, 39. The molded parts 37 are still held together by the not yet separated base 13 and immersed in a bath 40 and carried out. This bath 40 contains a suspension of an abrasive in a liquid, for example a suspension of emery in water. An ultrasound generator 41 is immersed in this bath 40 and in this liquid, which whirls up the suspended particles and thus causes abrasion of the surface pigment-containing surface layer of the individual molded parts 37. This is followed, as in FIG. 3, by the smoothing and hardening of the surface of the molded parts 37, here with the aid of a hot press with a pair of rollers 42, 43, and finally in the device 44, the punching out and, if necessary, the deburring and the cutting of the base 13.

Die in Fig. 5 schematisch dargestellte Vorrichtung dient der Ausführung eine Variante des Verfahrens. Für Teile dieser Vorrichtung nach Fig. 5, die gewissen Teilen der bereits beschriebenen Vorrichtungen äquivalent sind, werden die gleichen Bezugszeichen wie in den Fig. 2 bis 4 verwendet. Bei der Vorrichtung nach Fig. 5, wird ein profilierter Pressstrang 17 gebildet. In Fig. 5 erfolgt dies mit Hilfe von Walzen wie 11 und 12, zum Auspressen des Stranges 17 können aber auch andere an sich bekannte Vorrichtungen verwendet werden, beispielsweise eine Kolbenpresse und dergleichen. Die zu nutzende, keine Beschichtung mit Zusatzpigment aufweisende Oberfläche wird durch Schneiden des profilierten Pressstranges 17 gebildet. In Fig. 5 erfolgt dies durch Schneiden des profilierten Pressstranges 17 parallel zu seiner Vorschubrichtung mit Hilfe einer keilförmigen Aufschneidvorrichtung 45, so dass der profilierte Pressstrang 17 in Längsrichtung in zwei Teilprofile 24a, 24b geteilt wird. Anschliessend kann das Glätten der zu nutzenden Oberfläche 46a, 46b der Teilprofile 24a, 24b nach dem gleichen Prinzip, wie im Zusammenhang mit Fig. 4 beschrieben wurde, in demselben Verarbeitungsschritt erfolgen wie die Formgebung zur Bildung von voneinander trennbaren Formteilen aus mindestens einem der Teilprofile 24a, 24b. Auch die Vervollständigung der Aushärtung der Formteile kann in demselben Verarbeitungsschritt wie die Formgebung erfolgen.The device shown schematically in FIG. 5 is used to carry out a variant of the method. For parts of this device according to FIG. 5, which are equivalent to certain parts of the devices already described, the same reference numerals are used as in FIGS. 2 to 4. In the device according to FIG. 5, a profiled press strand 17 is formed. 5 this is done with the aid of rollers such as 11 and 12, but other devices known per se can also be used for pressing out the strand 17, for example a piston press and the like. The surface to be used, which has no coating with additional pigment, is formed by cutting the profiled extrusion 17. 5 this is done by cutting the profiled press strand 17 parallel to its direction of advance with the aid of a wedge-shaped cutting device 45, so that the profiled press strand 17 is divided in the longitudinal direction into two sub-profiles 24a, 24b. Subsequently, the smoothing of the surface 46a, 46b to be used of the partial profiles 24a, 24b can be carried out according to the same principle as described in connection with FIG. 4 in the same processing step as the shaping for the formation of separable molded parts from at least one of the partial profiles 24a , 24b. The hardening of the molded parts can also be completed in the same processing step as the shaping.

In einer nicht dargestellten Variante kann das Schneiden des profilierten Pressstranges normal zu seiner Vorschubrichtung erfolgen, so dass der Pressstrang in aufeinanderfolgende Stücke zerteilt wird. Auch hier kann das Glätten der zu nutzenden Oberfläche wie im vorangehenden in demselben Verarbeitungsschritt wie eine Formgebung zur Bildung von Formteilen aus den Stücken des Pressstranges erfolgen. Auch die Vervollständigung der Aushärtung der Formteile kann in demselben Verarbeitungsschritt wie die Formgebung erfolgen.In a variant, not shown, the profiled press strand can be cut normally to its direction of advance, so that the press strand is divided into successive pieces. Here too, the surface to be used can be smoothed as in the previous processing step in the same way as shaping to form molded parts from the pieces of the press strand. The hardening of the molded parts can also be completed in the same processing step as the shaping.

Claims (19)

1. A process for preparing pieces (34) of hard mass similar to decorative stone and presenting a smooth surface (33), in which pieces (7) of a granulate or a pasty mass cut in pieces (1) are coated with a pigment (6), then pressed together (11) and afterwards hardened to hard mass, characterized in that the pasty mass made of the pieces (10) coated with additional pigment and then pressed together is extruded and the so extruded rod (17) is subjected to a first incomplete hardening (20) after which the incompletely hardened pasty mass just is no more capable of flowing under its own weight, while before or after this first incomplete hardening there is formed a surface (24, 24a, 24b) of the rod (17) intended to be used which does not have a coating of additional pigment, then this surface intended to be used (29-32) is smoothed and finally the hardening of the pasty mass of the rod to a hard mass is completed.
2.A process according to claim 1, characterized in that the rod is formed to a coating (17) and coated on a base layer (13) and that the surface (24) intended to be used is formed by removing from the surface (24) of the coating (17) the surface layer containing additional pigment.
3. A process according to claim 2, characterized in that the smoothing of the surface (24) of the coating (17) is performed during the same treatment step than a forming (29) intended to form from the pasty mass of the coating pieces (34) which can be separated from each other.
4. A process according to claim 4, characterized in that the hardening of the formed pieces (34) is completed during the same treatment step than the forming (29).
5. A process according to claim 4, characterized in that the base layer (13) cannot be separated from the hardened coating (19) so that in the course of the separation of the formed pieces (34) from each other the base layer is separated, too.
6. A process according to claim 2, characterized in that the surface layer of the coating (17) containing additional pigment is removed by the effect of a solvent on the surface (24) of the coating.
7. A process according to claim 2, characterized in that the surface layer of the coating (17) containing additional pigment is removed by the effect of an abrasive means dispersed in a fluid on the surface (24) of the coating.
8. A process according to claim 7, characterized in that the abrasive means is suspended in a liquid.
9. A process according to claim 7, characterized in that the abrasive means is pulverized in an air stream.
10. A process according to one of claims 6 to 8, characterized in that the surface layer containing additional pigment is removed from the surface (24) of the coating (17) in the presence of ultrasound (40, 41).
11. A process according to claim 2, characterized in that the surface layer of the coating (17) containing additional pigment is removed by the effect of a mechanical means on the surface (24) of the coating.
12. A process according to claim 11, characterized in that the mechanical means is an adhesive tape.
13. A process according to claim 1, characterized in that the rod is formed to an extruded profile rod (17) and the surface of the rod intended to be used (46a, 46b) and which does not have a coating of additional pigment is formed by cutting (45) the extruded profile rod (17).
14. A process according to claim 13, characterized in that the cutting (45) of the extruded profile rod (17) is performed parallel to its direction of forward movement so that the extruded profile rod is divided in its longitudinal direction into at least two partial profiles (24a, 24b).
15. A process according to claim 14, characterized in that the smoothing of the surface of the rod intended to be used (46a, 46b) is performed during the same treatment step than a forming intended to form from at least one of the partial profiles (24a, 24b) the formed pieces which can be separated from each other.
16. A process according to claim 13, characterized in that the cutting of the extruded profile rod is performed normal to its direction of forward movement so that the extruded rod is divided into successive pieces.
17. A process according to claim 14, characterized in that the smoothing of the surface of the rod intended to be used is performed during the same treatment step than a forming intended to form the formed pieces from the pieces of the extruded rod.
18. A process according to claim 15 or 17, characterized in that the hardening of the formed pieces is completed during the same treatment step than the forming.
19. A process according to claim 1 for the manufacturing of formed pieces similar to decorative stone.
EP86906255A 1985-11-18 1986-11-04 Process for manufacturing parts having a flat surface from hard gem-stone material Expired - Lifetime EP0245313B1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
AT86906255T ATE55191T1 (en) 1985-11-18 1986-11-04 PROCESS FOR MAKING SMOOTH SURFACE PARTS FROM GEM-LIKE HARD MASS.

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
CH491085A CH663309GA3 (en) 1985-11-18 1985-11-18
CH4910/85 1985-11-18

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EP0245313A1 EP0245313A1 (en) 1987-11-19
EP0245313B1 true EP0245313B1 (en) 1990-08-01

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US (1) US4818570A (en)
EP (1) EP0245313B1 (en)
JP (1) JPS63501353A (en)
BR (1) BR8606986A (en)
CH (1) CH663309GA3 (en)
DE (1) DE3673160D1 (en)
WO (1) WO1987003109A1 (en)

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US5166230A (en) * 1991-09-16 1992-11-24 Stecker William M Method for producing a synthetic shaped article simulating marble, granite or the like
US7959991B1 (en) * 2003-06-30 2011-06-14 Albert C West Method of manufacturing an artificial stone material
ITUD20040101A1 (en) * 2004-05-17 2004-08-17 Delle Vedove Levigatrici Spa MACHINE TO FINISH AN OBJECT SUCH AS A PROFILE, A PANEL, OR SIMILAR
DE102015013167B4 (en) * 2015-10-09 2018-05-03 Audi Ag Method for processing glossy lacquer surfaces

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US1935985A (en) * 1931-05-02 1933-11-21 American Artificial Marble Com Artificial stone product and method of making same
US3012901A (en) * 1956-02-07 1961-12-12 Armstrong Cork Co Method and apparatus for orienting particles
US2835996A (en) * 1956-08-24 1958-05-27 Sr Romano De Paoli Ornamental terrazzo
CH394956A (en) * 1960-05-02 1965-03-15 Metalem Sa Process for working the surface of a clock face
NL263572A (en) * 1960-05-02
CH364428A (en) * 1960-06-28 1962-09-15 Humbert Prince Andre Machine for treating the surface of metal objects
US3381067A (en) * 1961-03-09 1968-04-30 Congoleum Nairn Inc Method of making a terrazzo plastic composition product
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US3359352A (en) * 1965-06-18 1967-12-19 Congoleum Nairn Inc Process for producing decorative surface covering
US3549398A (en) * 1967-04-03 1970-12-22 Fiber Industries Inc Method for manufacturing water-vapor permeable,synthetic,suede-like,material
GB1186545A (en) * 1967-04-21 1970-04-02 Ici Ltd Decorative Sheets or Other Articles of Plastics Materials
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WO1987003109A1 (en) 1987-05-21
DE3673160D1 (en) 1990-09-06
CH663309GA3 (en) 1987-12-15
US4818570A (en) 1989-04-04
JPS63501353A (en) 1988-05-26
EP0245313A1 (en) 1987-11-19
BR8606986A (en) 1987-12-22

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