EP3027824B1 - Flexible panel and method of production - Google Patents

Flexible panel and method of production Download PDF

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Publication number
EP3027824B1
EP3027824B1 EP14758666.3A EP14758666A EP3027824B1 EP 3027824 B1 EP3027824 B1 EP 3027824B1 EP 14758666 A EP14758666 A EP 14758666A EP 3027824 B1 EP3027824 B1 EP 3027824B1
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EP
European Patent Office
Prior art keywords
dispersion
compounds
aliphatic resin
flexible substrate
micron
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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Application number
EP14758666.3A
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German (de)
English (en)
French (fr)
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EP3027824A1 (en
Inventor
Ezio REVERBERI
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Individual
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Individual
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Publication of EP3027824A1 publication Critical patent/EP3027824A1/en
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    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F13/00—Coverings or linings, e.g. for walls or ceilings
    • E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
    • E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
    • E04F13/16—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements of fibres or chips, e.g. bonded with synthetic resins, or with an outer layer of fibres or chips
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/0056—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the compounding ingredients of the macro-molecular coating
    • D06N3/0063—Inorganic compounding ingredients, e.g. metals, carbon fibres, Na2CO3, metal layers; Post-treatment with inorganic compounds
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00—Flooring
    • E04F15/02—Flooring or floor layers composed of a number of similar elements
    • E04F15/10—Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials
    • E04F15/102—Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials of fibrous or chipped materials, e.g. bonded with synthetic resins
    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47G—HOUSEHOLD OR TABLE EQUIPMENT
    • A47G23/00—Other table equipment
    • A47G23/06—Serving trays

Definitions

  • the present invention concerns a flexible panel and a corresponding method of production, which constitutes an unusual product, innovative because of the composition of the material and its possible uses, and a method that allows to transform a flexible substrate, such as a soft fabric, of vegetable origin such as for example jute or cotton, or other, or synthetic, inorganic or artificial, or a piece of hide or a sheet of metal, in particular aluminum, possibly also a sheet of self-adhesive aluminum, into a panel or sheet, comparable for example to a robust hide or cloth, consisting of stones or metals, which will be hard but at the same time flexible so as to be able to adapt to cover every type of surface, object or shape.
  • a flexible substrate such as a soft fabric, of vegetable origin such as for example jute or cotton, or other, or synthetic, inorganic or artificial
  • a piece of hide or a sheet of metal in particular aluminum, possibly also a sheet of self-adhesive aluminum
  • solutions are typically used which are less thick and weight, such as plastic laminates, PVC slabs, linoleum.
  • carpet Another material which is not very thick or heavy and easy to lay is carpet but, as is known, this material is not very satisfactory because of its well known retention of dirt, because it is difficult and costly to keep clean and so it is not hygienic for living areas.
  • EP2586814 A1 discloses a self-crosslinking polyhydroxy polyurethane resin, that can be used to make products, such as imitation leather, a skin material for car interior or home electric appliance component, or weather strip to prevent wind or rain from penetrating through gap of a door.
  • Patent EP-A-0.562.282 describes a water-based varnish to make covering films for furnishing elements made of wood, polyester, polyurethane, polyacrylic, polyepoxides, metal, or covered with a different water-based varnish.
  • the water-based varnish of EP-A-0.562.282 has high resistance to chemical agents and to abrasion, and has an esthetic appearance similar to that of solvent-based varnishes.
  • This varnish provides a mixture of a first component that consists of water-based dispersions of acrylic and urethane polymers and a second component that consists of a liquid poly-isocyanide compound as such, or in a solution with ethylacetate.
  • the varnish provides to use silica oxide as filler, to confer for example hardness, rigidity and resistance to abrasion.
  • the poly-isocyanide is used to reticulate the acrylic-urethane polymer material, and therefore has the properties of hardness, rigidity and resistance to abrasion of reticulated polyurethane bi-component systems, similar to solvent-based systems; it therefore does not have any properties of flexibility such as to be adaptable and shapeable to cover any type of surface, object or shape.
  • Document GB-A-2.429.419 describes a hydrophobic covering and a hydrophylic covering applied on respective surfaces of a material for an anti-collapsible construction, in particular a fibrous panel for ceilings, in particular for sound-proofing.
  • This solution therefore describes a rigid and structured panel, commonly used suspended to the ceiling for sound-proofing, absolutely unsuitable for covering every type of surface, object or shape.
  • One purpose of the present invention is to overcome the shortcomings of the state of the art, which provide to consolidate, protect and/or finish the surfaces of materials of already existing articles such as wood, sheet metals, metals and others, proposing the possibility to make a new, intrinsic and completely innovative material, consisting of the association of mineral raw materials, such as stones or metals, in a homogenous compound, in the form of a flexible panel, and a method of production, which represent advantageous alternatives to hides or flexible cloths used in the production of leather goods, luggage or upholstery that can be used without the need for polluting processes or that consume fossil fuels.
  • Another purpose is to supply a flexible panel and a method of production that represent advantageous alternative solutions to traditional stone materials such as terracotta, stone or marble in building restoration, where it is very important to prevent the demolition of old floorings and coverings, without needing to use materials of a lesser thickness and weight, without quality and personalization, as happens with plastic laminates, thin parquet and vinyl flooring.
  • the Applicant has devised, tested and embodied the present invention to overcome the shortcomings of the state of the art and to obtain these and other purposes and advantages.
  • forms of embodiment described here concern a cold processed flexible substrate, at least partly covered or impregnated with a dispersion of water-based aliphatic resin in which granules of stone or mineral material are homogeneously distributed, wherein said dispersion of water-based aliphatic resin comprises: -one or more compounds chosen from a group comprising polyurethane compounds:-one or more compounds chosen from a group comprising acrylic compounds: and-one or more compounds chosen from a group comprising styrene compounds: wherein said stone or mineral material is chosen from a group comprising terracotta, stone, marble, crystals, quartzes, metals in general, in particular bronze, steel or iron, wherein in the case of terracotta, the latter has a grain size from 0.3 mm to 1 mm and the terracotta and the dispersion of water-based aliphatic resin are provided in a ratio of 1 part in weight of dispersion of aliphatic resin and 3 parts in weight of
  • the flexible substrate can be chosen from: a length of fabric or hide or a sheet of metal, in particular aluminum for example, possibly also a sheet of self-adhesive metal, in particular a sheet of self-adhesive aluminum.
  • a flexible panel is obtained that can be an innovative hide or cloth or sheet of metal consisting of a flexible substrate, for example a natural vegetable fabric, hide or sheet of metal, in particular aluminum, reinforced with particles of stones, marble, terracotta, crystals, various metals; it is hard but malleable, adaptable to cover every type of surface, object or shape, water-proof, stain-proof and fire-proof.
  • a flexible substrate for example a natural vegetable fabric, hide or sheet of metal, in particular aluminum, reinforced with particles of stones, marble, terracotta, crystals, various metals; it is hard but malleable, adaptable to cover every type of surface, object or shape, water-proof, stain-proof and fire-proof.
  • the fabric can be formed from fibers of natural origin, such as vegetable, animal or mineral, or techno-fibers, such as artificial, synthetic or inorganic fibers.
  • natural fibers usable in forms of embodiment can be vegetable fibers, chosen for example from a group comprising: cotton, linen, hemp, jute, ramie (or nettle yarn), sisal, coconut, Spanish broom, hibiscus, straw, bamboo.
  • natural fibers usable in forms of embodiment can be animal fibers chosen for example from a group comprising: wool, hair, silk, horsehair, fine linen.
  • natural fibers usable in forms of embodiment can be mineral fibers chosen for example from a group comprising: asbestos, metal wires, glass wool.
  • synthetic fibers usable in forms of embodiment can be chosen from a group comprising: acrylic, modacrylic (acrylic modified to be flame-proof), polyamide (nylon), polyester, polypropylene, polyethylene, vinyl chloride, polyurethane (elastam), Teflon (Gore-Tex), aramid (Kevlar).
  • inorganic fibers usable in forms of embodiment can be chosen from a group comprising: textile glass, carbon fibers, basalt, metal fibers (copper, silver, gold, steel), metalized fibers.
  • artificial fibers usable in forms of embodiment can be chosen from a group comprising: rayon, modal, cupro, acetate, triacetate, lyocell, rubber or caoutchouc, viscous or artificial silk.
  • the present invention also concerns a method for the production of a flexible panel, which comprises at least the following steps:
  • the homogeneous mixture can be applied to the flexible substrate by means of one or more of the following operations:
  • the choice of one or the other of these operations can be determined by the typical absorption of the substrate material. For example, if the substrate material is highly absorbent, the immersion system can be used, if the substrate material is averagely absorbent the mixture can be spread or applied using a spatula, while if the substrate material is non-absorbent the mixture can be sprayed.
  • kits for the application of a flexible panel as described above comprising:
  • the object of the present invention is characterized in that it is a new, unusual and very beautiful product from both an esthetic and material point of view, consisting of granules of real stone, marble, crystals, metals, possibly also precious metals, which, through a cold production process transforms soft and delicate fabrics such as cotton or jute or others, into a strong material or hide, hard but at the same time flexible, malleable, workable with scissors and stitches, highly resistant to scratches, unalterable by water, resistant to penetration by stains, fire-proof, restorable over time; with these properties it is safe to use in various environments, adapting to every architectural element, such as stairs, coverings, furniture, furnishings, both in the building trade and in the shipbuilding, aeronautical and railway industries.
  • the grain size or granulometric distribution used for the production of handmade terracotta is comprised of grains from 0.3 mm to 1 mm, while the grain size of marble or quartzes can be considered in a curve that can be determined between 0 ⁇ m (micron) - 45 ⁇ m (micron), or from 0 ⁇ m (micron) to 160 ⁇ m (micron); to make white marble of the Carrara type very fine grain sizes are used from 0 ⁇ m to 50 ⁇ m.
  • the invention is characterized by the fact that the choices of the grain size are determined in a preliminary step for each type of stone or metal material in technical files which will be made available to the person in charge of production.
  • the technical files will be available together with the sample made, with a note of the grain size used.
  • the invention is characterized by the determination of the proportions of water-based aliphatic resins with respect to the granules, which are provided in a ratio which varies depending on the hardness and simultaneous malleability to be obtained.
  • the ratios are determined during the production planning step and the corresponding values will be shown in the production files, as described above.
  • the invention is characterized by the determination of the proportions of the compound of resins and granules as described above; by way of non-restrictive example, we shall now give some cases: handmade terracotta: ratio of 1 (one) part in weight of the consolidating compound and 3 (three) parts of terracotta granules with a granulometric curve from 0 mm to 1 mm; bronze: ratio of 1 (one) part of the consolidating compound and 5 (five) parts of bronze granules of 100 mesh, while the parts of bronze will be 4 (four) if the grains are 200 mesh.
  • the invention is characterized for its different and variable proportions which, as shown above, differ depending on the grain size and absorbency of the mineral involved in the production, on the hardness, malleability and texture to be conferred on the finished product of the invention.
  • proportions even if indicated as a non-restrictive example, cannot be determined in any other way than on the basis of tests carried out concurrently to the production plan, with specific production tables being drawn up where the specifications will be indicated.
  • the invention is characterized by the production steps which provide to mix the compound of water-based aliphatic resins with a stirrer with helical impellers at a low number of revs, to pour the compound into a whisk or blade stirrer and to introduce the granules, stirring the compound at low and average number of revs to obtain a homogeneous fluid mortar.
  • the introduction of the fluid mortar is introduced into non-stick silicone rubber trays of the size provided for the production.
  • the invention can provide to immerse the flexible substrate, such as for example a length of cloth, fabric or hide or sheet of metal, in particular aluminum, possibly even a sheet of self-adhesive metal, in particular a sheet of self-adhesive aluminum, of a thickness which can vary from 0.5 mm to 10 mm, in particular from 1 mm to 8 mm, depending on the result to be obtained; to extract the fabric with suitable pliers and to position the fabrics on a plane of silicone rubber or nylon made anti-adherent; to dry at room temperature of no less than 15°C and with humidity no higher than 50%; to sand, de-powder, and apply/impregnate with a flame-proof liquid; to obtain a stain-resistant protection, and to trim the pieces; to preserve them on a ventilated shelf and then to pack them in cardboard boxes for commercial delivery.
  • the flexible substrate such as for example a length of cloth, fabric or hide or sheet of metal, in particular aluminum, possibly even a sheet of self-adhe
  • the invention provides to distribute, spread, to apply with a spatula or spray the fluid and homogeneous mortar on one or both sides of the flexible substrate.
  • the invention is characterized by its hardness yet simultaneous malleability, flexibility and deformability, which can allow it to bend by as much as 100° in the solid mass of the fabric, and not only in the free gaps as happens for other articles laid on a mesh.
  • the invention is characterized by the fact that it is possible to mix together materials which are very different from each other, such as stones, terracotta, metals, possibly even precious metals, combinable with each other as desired.
  • the invention thus differs from yarns that consist of only one element whether it is organic or mineral.
  • Forms of embodiment described here concern the cold transformation of a flexible substrate, such as for example a length of fabric ( fig. 1 ) or a fabric of woven fibers, of natural origin, in particular vegetable, or synthetic, inorganic or artificial, or a piece of hide or a sheet of metal, in particular aluminum, into a flexible panel according to the invention, which represents an innovative "mineral hide or fabric", hard but flexible, adaptable and workable both by cutting with scissors and with stitching, with fire-proof properties, unaffected by water and impenetrable by stains, even oil or grease stains.
  • a flexible substrate such as for example a length of fabric ( fig. 1 ) or a fabric of woven fibers, of natural origin, in particular vegetable, or synthetic, inorganic or artificial, or a piece of hide or a sheet of metal, in particular aluminum
  • the invention can be realized by incorporating into the mass of the flexible substrate, such as fabric, natural or synthetic, inorganic or artificial, or piece of hide or sheet of metal, in particular aluminum, the granules of materials chosen for the type of production, for example terracotta, stone, metal, by immersion in a homogeneous mixture in which the granules and a dispersion of a water-based aliphatic resin are present, that is, a compound of water-based aliphatic resins, without solvents and hydraulic binders that will consolidate in a cold process, at room temperature, without having recourse to ovens for baking them.
  • spraying apparatuses can be used, for example, able to spray mixtures that include inert components in granule form, for example with a grain size of up to 3 mm.
  • the choice of which of the variants to use can depend for example on the viscosity of the homogeneous mixture and/or the nature or type of flexible substrate on which the homogeneous mixture is applied.
  • the resins can be balanced in quantity and quality so as to produce a hardening comparable to the hardness of the mineral element chosen for the compound, at the same time keeping the malleability typical of fabrics.
  • the material appearance of the invention can be that of the mineral of which it consists, and therefore there are numerous variables that can be obtained, both due to the nature of the mineral compound and its texture, which can be felt and not only seen, as happens instead with materials reproduced using photographic and typographic processes.
  • the invention is also characterized by its waterproof properties, and for this reason it is perfectly compatible for use in exteriors; the hide or fabric according to the present invention does not absorb also elements of dirt carried by oil or grease and, if it comes into contact with fire, it carbonizes without a flame and without giving off toxic fumes.
  • the present invention can also be advantageously used in many fields of manufacturing, such as leather goods, the production of bags, suitcases, trunks and similar, clothing, footwear, gold or jewelry, or coverings for furniture, in furnishing, stairs, columns, floors and various architectural components.
  • the invention allows to lay, over the old coverings, quality materials such as natural stones, handmade terracotta or precious metals which in addition to low thickness and weight, have the added value of the quality of the materials, personalized finish and, thanks to the invention, the malleability needed to adapt to every type of shape and surface.
  • the invention is an innovative product similar to hides and fabrics, but with the advantage that it has a high esthetic quality and material, and a strength given by the mineral materials of which it is made, together with the malleability which allows a very varied use as a covering material.
  • the incorporation of the mineral granules in the mass of the flexible substrate is achieved through a process of consolidation without baking in ovens, totally without solvents, without consuming any fossil fuels and therefore in an environmentally sustainable manner.
  • the fabrics and compounds according to the invention are made of recycled materials, discarded because of breakages or unsold merchandise lying in the yards.
  • the granules are obtained by granulating with suitable hammer mills, they are de-powdered and progressively sieved, with the intention of obtaining determinate ranges of grain sizes.
  • the invention does not absorb water or dirt and, in the event of fire, carbonizes without producing flames or toxic vapors: this gives a considerable improvement in performance compared with vegetable and animal fabrics which absorb water and dirt and almost always produce flames when they burn.
  • the present invention allows to finish materials such as stone, handmade terracotta ( fig. 2 ), metal materials like bronze ( fig. 3 ), steel, and iron, with thin and light materials, without having to renounce beauty and architectural value.
  • the invention also gives a big advantage over laying traditional slabs and tiles, in terms of flexibility in preparation and laying, and also shorter times for production and laying.
  • the same advantage can be found in shipbuilding, aeronautics and train building where, in addition to its lightness and thinness, the invention's qualities of anti-slip safety, high resistance to penetration by dirt, resistance to wetting and inertia to fire are greatly appreciated.
  • the panels according to the present invention although they consist of materials of considerable value like precious stones, handmade terracotta, marble and metal compounds, can be laid quickly, at reduced cost, just as happens for example for laying carpet.
  • the present invention helps to overcome various limits such as:
  • the fluid and homogenized mortar formed by the homogeneous mixture of inert materials and dispersion of water-based aliphatic resins may be spread or applied with a spatula on one or both sides of the flexible substrate (for example if the substrate is averagely absorbent), or again, the mortar can be sprayed on one or both sides of the flexible substrate (for example if the substrate is not absorbent).
  • a flexible substrate as used in the forms of embodiment described here can be at least one element selected from the group consisting of: a length of fabric or fiber, natural, synthetic, or artificial, mineral, intending both warp and weave fabric, woven fabric, or made with other techniques, both non-woven fabric, or sheets or lengths of hide, intending both natural hide and imitation or synthetic hide, or sheets of metal, in particular thin sheets of metal, for example sheets of aluminum, possibly also sheets of self-adhesive metal, in particular sheets of self-adhesive aluminum, and similar articles.

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Inorganic Chemistry (AREA)
  • Textile Engineering (AREA)
  • Laminated Bodies (AREA)
  • Decoration Of Textiles (AREA)
  • Chemical Or Physical Treatment Of Fibers (AREA)
EP14758666.3A 2013-07-29 2014-07-24 Flexible panel and method of production Active EP3027824B1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
IT000029A ITAR20130029A1 (it) 2013-07-29 2013-07-29 Innovativa pelle o panno, composto un da tessuto vegetale naturale rinforzato nella massa con particelle di pietre, marmi, cotto, cristalli, metalli vari; duro ma duttile, adattabile a rivestire ogni tipo di superficie, oggetto o forma, inattaccabile
PCT/IB2014/063385 WO2015015380A1 (en) 2013-07-29 2014-07-24 Flexible panel and method of production

Publications (2)

Publication Number Publication Date
EP3027824A1 EP3027824A1 (en) 2016-06-08
EP3027824B1 true EP3027824B1 (en) 2021-03-17

Family

ID=49487482

Family Applications (1)

Application Number Title Priority Date Filing Date
EP14758666.3A Active EP3027824B1 (en) 2013-07-29 2014-07-24 Flexible panel and method of production

Country Status (4)

Country Link
EP (1) EP3027824B1 (ru)
EA (1) EA201690273A1 (ru)
IT (1) ITAR20130029A1 (ru)
WO (1) WO2015015380A1 (ru)

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
IT201800002939A1 (it) * 2018-02-22 2019-08-22 Alice Zantedeschi Procedimento per la fabbricazione di una membrana adattata per accoppiamento ad un tessuto, e prodotto così ottenuto
CN109118968B (zh) * 2018-10-22 2023-10-03 五邑大学 一种电流驱动的柔性显示器件

Family Cites Families (5)

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Publication number Priority date Publication date Assignee Title
US3503841A (en) * 1966-05-13 1970-03-31 Grace W R & Co Foamed polystyrene bonded to fiber filled polyvinyl chloride sheet
IT1254549B (it) * 1992-03-23 1995-09-25 Prodotti vernicianti all'acqua, bicomponenti, a base acrilica-poliuretanica.
US7125601B1 (en) * 2000-10-18 2006-10-24 3M Innovative Properties Company Integrated granule product
US7851052B2 (en) * 2005-08-23 2010-12-14 Awi Licensing Company Coating system for sag resistant formaldehyde-free fibrous panels
CN102958978B (zh) * 2010-06-24 2014-11-19 大日精化工业株式会社 自交联型多羟基聚氨酯树脂及其制造方法、以及使用该树脂而成的相关材料

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Also Published As

Publication number Publication date
WO2015015380A1 (en) 2015-02-05
EP3027824A1 (en) 2016-06-08
EA201690273A1 (ru) 2016-07-29
ITAR20130029A1 (it) 2015-01-30

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