GB2164340A - Resin-based building materials - Google Patents

Resin-based building materials Download PDF

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Publication number
GB2164340A
GB2164340A GB08423597A GB8423597A GB2164340A GB 2164340 A GB2164340 A GB 2164340A GB 08423597 A GB08423597 A GB 08423597A GB 8423597 A GB8423597 A GB 8423597A GB 2164340 A GB2164340 A GB 2164340A
Authority
GB
United Kingdom
Prior art keywords
building material
resin
weight
mould
catalyst
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.)
Granted
Application number
GB08423597A
Other versions
GB8423597D0 (en
GB2164340B (en
Inventor
Henry Walsh
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Marshalls Mono Ltd
Original Assignee
Marshalls Mono Ltd
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Marshalls Mono Ltd filed Critical Marshalls Mono Ltd
Priority to GB08423597A priority Critical patent/GB2164340B/en
Publication of GB8423597D0 publication Critical patent/GB8423597D0/en
Publication of GB2164340A publication Critical patent/GB2164340A/en
Application granted granted Critical
Publication of GB2164340B publication Critical patent/GB2164340B/en
Expired legal-status Critical Current

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Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F27—FURNACES; KILNS; OVENS; RETORTS
    • F27D—DETAILS OR ACCESSORIES OF FURNACES, KILNS, OVENS, OR RETORTS, IN SO FAR AS THEY ARE OF KINDS OCCURRING IN MORE THAN ONE KIND OF FURNACE
    • F27D1/00—Casings; Linings; Walls; Roofs
    • F27D1/0003—Linings or walls
    • F27D1/0006—Linings or walls formed from bricks or layers with a particular composition or specific characteristics
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B26/00—Compositions of mortars, concrete or artificial stone, containing only organic binders, e.g. polymer or resin concrete
    • C04B26/02—Macromolecular compounds
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K3/00—Use of inorganic substances as compounding ingredients
    • C08K3/01—Use of inorganic substances as compounding ingredients characterized by their specific function
    • C08K3/013—Fillers, pigments or reinforcing additives

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Organic Chemistry (AREA)
  • Ceramic Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Structural Engineering (AREA)
  • Materials Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Health & Medical Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Medicinal Chemistry (AREA)
  • Polymers & Plastics (AREA)
  • Compositions Of Macromolecular Compounds (AREA)

Abstract

A building material comprises a resin and three aggregates of different grain sizes. The building material may be manufactured closely to resemble natural stone and may be used for replacing natural stone or roofing slates, while at the same time being cheaper, lighter and stronger. A preferred embodiment comprises flint, silica sand, silica powder, methyl methacrylate resin and a catalyst in the form of methyl ethyl ketone peroxide. The invention includes a mould formed by allowing a mould material to come into contact with another building material, for example a natural roofing slate or stone roofing tile.

Description

SPECIFICATION Building materials The invention relates to building materials, and in particular, but not exclusively, to building materials which resemble natural building materials such as slate and stone.
Many houses have a roof which is covered with slates. When these slates require replacing it is often found that is difficult to obtain replacements which are of the same size, colour and texture as the originals.
This may be due to exhaustion of supplies of a particular type of material or might be because of a variation in colour of the stone. If only a few slates or stones are replaced, it may mean that these are different from the rest of the roof. If all the slates or stones are replaced, the whole roof might be a different colour from the roofs of surrounding buildings. This is undesirable since houses in certain areas are traditionally covered only with certain types of slate and stone, which have a definite size, shape, thickness and texture. To produce these traditional roofing materials is a skilled and time-consuming process, and together with the facts that much natural stone is lost during its shaping and cutting and that certain natural stones are becoming scarce, it is expensive to repair or replace a roof.
Accordingly, one aspect of the invention provides a building material comprising a resin and three aggregates of different grain sizes.
This building material, which may closely resemble natural stone, can be used as a replacement for natural stone, while at the same time being cheaper, lighter and stronger, and more resistant to frost cracking than, natural stone.
One of the aggregates may comprise flint One of the aggregates may comprise silica sand.
One of the aggregates may comprise silica powder.
The aggregates may be in the following relative proportions: Percentage of total Aggregate weight ofaggregate Flint 45-75% Silica Sand 20-45% Silica powder 1-20% Preferably, the aggregates are in the following relative proportions: Percentage of total Aggregate weight of aggregate Flint 60.30% Silica Sand 30.15% Silica powder 9.55% Preferably the weight of the resin is equal to between 10% and 25% of the weight of the aggregate and preferably is equal to between 15% and 20% of the weight of the aggregate.
Preferably the resin is set by means of a catalyst and may be cured at ambient temperature or by application of heat.
Preferably the weight of the catalyst is between 0.5 and 2.5% of the total weight of the mixture, and is preferably between 1% and 2% of the total weight of the mixture.
The catalyst may comprise methyl ethyl ketone peroxide.
The constituents of the building material may be in the following relative proportions: Constituent Percentage oftotal weight Flint 40-60% Silica sand 15 -40% Silica powder 1 - 15% Resin 5-25% Catalyst 1-2% Preferably, the constituents are in the following relative proportions: Constituent Percentage of total weight Flint 50.74% Silica sand 25.37% Silica powder 8.03% Resin 14.58% Catalyst 1.48% The grains of flint are preferably generally 1-2mm in size, and the silica powder may be H2 and/or H5 silica powder.
The resin may comprise one or more of polyester resin, epoxy resin and methacrylate resin. The methacrylate resin may be a methyl methacrylate resin.
The resin may be coloured.
The invention includes an artificial roofing slate or artificial stone tile according to the invention.
It is important when manufacturing artificial building materials that they should look similar as possible to the natural building material. For example, slates from different areas cleave in different manners, producing slates with a characteristic surface shape.
Accordingly, a second aspect of the invention provides a mould for a settable building material the mould taking its shape from another building material.
Preferably, the mould is formed by allowing the mould material to come into contact with the other building material and allowing the mould material to harden.
The mould material may comprise an elastomer.
The other building material may comprise a roofing slate or a stone roofing tile.
The invention includes a building material produced in a mould according to the invention.
A specific embodiment of the invention will now be described, with reference to the following example.
A building material, suitable for the manufacture of artificial, imitation Welsh Blue roofing slates comprises the following materials: Material Weight per imitation slate 1-2mm flint 10309 Silica sand 5159 H5 silica powder 1639 Pigmented, general purpose resin 2929 Methyl ethyl ketone peroxide catalyst 309 In practice, a plurality of artificial slates is manufactured at the same time, with the materials in the above relative proportions. In order to manufacture the building material the flint, the silica sand and the H5 silica powder are thoroughly mixed together. The resin and catalyst are then added and the whole contents are thoroughly mixed to ensure even distribution of the constituent materials.
The mixture is then placed into female moulds. The female moulds are of elastomeric material and are themselves moulded from a real slate in order to have the same external shape, texture, surface and general appearance as the particular natural slate which is being imitated. The moulds also contain two conical studs on the base, to provide nail holes in the finished tiles. A flat male mould is pressed tightly onto the exposed surface of the mixture to distribute the mixture throughout the female mould and to ensure that the pattern on the female mould is reproduced on the finished product. the female mould is heated by means of hot water, and the male mould may be similarly heated. Heating of the moulds heats the mixture and accelerates the curing.When the artificial slates are removed from the moulds, they are flexible, and so they are positioned between boards so that they will be flat when they are curing. The artificial slates are left to cure for about a week, at the end of which they are sufficiently hard and stable to allow them to be used in building and thus be exposed to weathering. In use, the artificial slates can be used in exactly the same manner as natural slates, either with other artificial slates or in conjunction with natural slates.
The invention is not restricted to the details of the foregoing embodiment. For example, the proportions of the materials used may be altered in order to produce a material which more closely resembles a given natural material. For example, it may be desirable to alter the proportions in order to imitate Westmorland Slate or York Stone. The material need not be for imitating natural stone. The material may be used for imitating other building materials such as tiles, or may be used as a building material in its own right, for example as cladding, without resembling any other building material in particular. Consequently, different moulds may be used. For example, the mould may itself be moulded from a Westmorland Slate or York Stone.
It may be desirable to alter the size of the aggregate. The size of the silica powder aggregate may be changed. For example H2 silica powder may be used instead of or as well as H5 silica powder. The resins may contain ultra-violet stabilising or fire retardant additives and the resin itself may comprise polyester resin, expoxy resin or methylmethacrylate resin, and may or may not need a catalyst.
Instead of, or as well as, using a male mould to ensure that the mixture fills the female mould thoroughly, a pressure moulding technique may be used, in which the mixture is injected into the female mould with a large force, thus helping to fill the mould completely. Alternatively, or in addition, the mould may be vibrated to further assist in filling the mould.
Instead of using a conventional mould into which the mixture is poured, the mixture may be in the form of a plastically deformable mixture which is fed through two rollers, one of which has the pattern of a building material, e.g. slate, embossed upon it. The rollers may be heated to assist in the curing of the resin.
Another possibility is to feed the mixture onto a conveyor belt, which may be heated and/orvibrating, which is embossed with the pattern of a building material, e.g. a slate.
The shape of the mould may be varied to produce building materials for a particular purpose. For example, the mould may be shaped to produce ridge tiles or other special fitments.

Claims (24)

1. A building material comprising a resin and three aggregates of different grain sizes.
2. A building material as claimed in claim 1, in which one of the aggregates comprises flint.
3. A building material as claimed in claim 1 or claim 2, in which one of the aggregates comprises silica sand.
4. A building material as claimed in any one of claims 1 to 3, in which one of the aggregates comprises silica powder.
5. A building material as claimed in any one of claims 1 to 4, in which the aggregates comprise 45 to 75% by weight of flint, 20 to 45% by weight of silica sand, and 1 to 20% by weight of silica powder.
6. A building material as claimed in claim 5, in which the aggregates comprise 60.30% by weight of flint, 30.15% by weight of silica sand, and 9.55% of silica powder.
7. A building material as claimed in any one of the preceding claims, in which the weight of the resin is equal to between 10% and 25% of the weight of the aggregate.
8. A building material as claimed in claim 7, in which the weight of the resin is equal to between 15% and 20% of the weight of the aggregate.
9. A building material as claimed in any one of the preceding claims, in which the resin is set by means of a catalyst.
10. A building material as claimed in claim 9, in which the weight of the catalyst is between 0.5 and 2.5% of the total weight of the mixture.
11. A building material as claimed in claim 10, in which the weight of the catalyst is between 1% and 2% of the total weight of the mixture.
12. A building material as claimed in any one of claims 9 to 11, in which the catalyst is methyl ethyl ketone peroxide.
13. A building material as claimed in claim 1, in which the constituents have the following proportions by weight: Flint 40- 60% Silica sand 15-40% Silica powder 1 - 15% Resin 5-25% Catalyst 1 - 2%
14. A building material as claimed in claim 13, in which the constituents have the following proportions by weight: Flint 50.74% Silica sand 25.37% Silica powder 8.03% Resin 14.58% Catalyst 1.48%
15. A building mixture as claimed in claim 1, comprising grains of flint of from 1 to 2 mm in size.
16. A building material as claimed in claim 1, comprising silica powder in the form of H2 and/or H5 silica powder.
17. A building material as claimed in claim 1, in which the resin comprises one or more of polyester resin, epoxy resin and methacrylate resin.
18. A building material as claimed in claim 1, in which the resin comprises methyl methacrylate resin.
19. A building material as claimed in any preceding claim, in which the resin is coloured.
20. A mould for a settable building material, the mould taking its shape from another building material.
21. A mould as claimed in claim 20, formed by allowing the mould material to come into contact with the other building material and allowing the mould material to harden.
22. A mould as claimed in claim 20 or claim 21, in which the mould material comprises an elastomer.
23. A mould as claimed in any one of claims 20 to 22, in which the other building material comprises a roofing slate, or a stone roofing tile.
24. An artificial roofing slate or artificial stone tile constructed according to any one of claims 1 to 19, or using the mould as claimed in any one of claims 20 to 23.
GB08423597A 1984-09-18 1984-09-18 Resin-based building materials Expired GB2164340B (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
GB08423597A GB2164340B (en) 1984-09-18 1984-09-18 Resin-based building materials

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GB08423597A GB2164340B (en) 1984-09-18 1984-09-18 Resin-based building materials

Publications (3)

Publication Number Publication Date
GB8423597D0 GB8423597D0 (en) 1984-10-24
GB2164340A true GB2164340A (en) 1986-03-19
GB2164340B GB2164340B (en) 1988-01-20

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Family Applications (1)

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Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0400244A1 (en) * 1987-12-01 1990-12-05 Societe Des Schistes Bleus Du Cotentin Covering elements and processes and devices for manufacturing same
WO1993007011A1 (en) * 1991-09-30 1993-04-15 Eurotech Technologies Inc. Acrylic-containing facing material for buildings
US5268028A (en) * 1987-08-25 1993-12-07 Oldcastle, Inc. Lightweight concrete roof tiles and similar products
ES2148019A1 (en) * 1996-10-16 2000-10-01 Inigo Valeriano Reyes Limestone, silica and resins based agglomerate consists of nummulitic limestone with additives improving strength and machinability
ES2187313A1 (en) * 1999-09-01 2003-06-01 Cosentino Sa Fabrication of artificial e.g. decorative stone blocks consists of mixing of liquid resin with liquid pigments and e.g. crushed granite fractions
EP1611992A1 (en) * 2004-05-25 2006-01-04 Tamko Roofing Products Inc. Method of forming a molding surface for a composite shingle mold
BE1016807A3 (en) * 2005-10-13 2007-07-03 Guido Cardinaels Plastic cover piece, e.g. roof covering element, comprises low density layer and high density layer containing visible filler material

Citations (13)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB855007A (en) * 1955-11-28 1960-11-23 Terrazzite Ltd Polished floor or other building surface and synthetic resin based composition therefor
GB955090A (en) * 1959-08-24 1964-04-15 Nippon Telegraph & Telephone Improvements in reinforced plastics
GB1020545A (en) * 1961-08-30 1966-02-23 Reliance Steel Prod Co Concrete based upon epoxy resins and method of making the same
GB1373214A (en) * 1971-11-04 1974-11-06 Ici Ltd Composite materials
GB1390301A (en) * 1972-07-28 1975-04-09 Atomic Energy Commission Glass polymer composites
GB1464243A (en) * 1974-07-31 1977-02-09 Ici Ltd Composite materials
GB1592346A (en) * 1976-05-24 1981-07-08 Kroyer K K K Moulding compositions comprising glass particles and a polymeric binder
US4299761A (en) * 1979-03-19 1981-11-10 Rohm And Haas Company Polymer concrete compositions, methods of application thereof, and polymerized products thereof
GB2124201A (en) * 1982-07-20 1984-02-15 Fidalgo Lopez B Process for the reconstitution of slates
WO1984002708A1 (en) * 1981-03-17 1984-07-19 Horton Co Polymer concrete comprising furfuryl alcohol resin
GB2134120A (en) * 1982-10-28 1984-08-08 Herman Clark Wadsworth Corrosion resistant materials and method of making same
GB2135324A (en) * 1983-02-25 1984-08-30 Diasol Sarl Process for manufacture of slates from waste slate
GB2157704A (en) * 1984-02-14 1985-10-30 E H Bradley Building Products Building materials; artificial slate

Patent Citations (13)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB855007A (en) * 1955-11-28 1960-11-23 Terrazzite Ltd Polished floor or other building surface and synthetic resin based composition therefor
GB955090A (en) * 1959-08-24 1964-04-15 Nippon Telegraph & Telephone Improvements in reinforced plastics
GB1020545A (en) * 1961-08-30 1966-02-23 Reliance Steel Prod Co Concrete based upon epoxy resins and method of making the same
GB1373214A (en) * 1971-11-04 1974-11-06 Ici Ltd Composite materials
GB1390301A (en) * 1972-07-28 1975-04-09 Atomic Energy Commission Glass polymer composites
GB1464243A (en) * 1974-07-31 1977-02-09 Ici Ltd Composite materials
GB1592346A (en) * 1976-05-24 1981-07-08 Kroyer K K K Moulding compositions comprising glass particles and a polymeric binder
US4299761A (en) * 1979-03-19 1981-11-10 Rohm And Haas Company Polymer concrete compositions, methods of application thereof, and polymerized products thereof
WO1984002708A1 (en) * 1981-03-17 1984-07-19 Horton Co Polymer concrete comprising furfuryl alcohol resin
GB2124201A (en) * 1982-07-20 1984-02-15 Fidalgo Lopez B Process for the reconstitution of slates
GB2134120A (en) * 1982-10-28 1984-08-08 Herman Clark Wadsworth Corrosion resistant materials and method of making same
GB2135324A (en) * 1983-02-25 1984-08-30 Diasol Sarl Process for manufacture of slates from waste slate
GB2157704A (en) * 1984-02-14 1985-10-30 E H Bradley Building Products Building materials; artificial slate

Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5268028A (en) * 1987-08-25 1993-12-07 Oldcastle, Inc. Lightweight concrete roof tiles and similar products
EP0400244A1 (en) * 1987-12-01 1990-12-05 Societe Des Schistes Bleus Du Cotentin Covering elements and processes and devices for manufacturing same
WO1993007011A1 (en) * 1991-09-30 1993-04-15 Eurotech Technologies Inc. Acrylic-containing facing material for buildings
ES2148019A1 (en) * 1996-10-16 2000-10-01 Inigo Valeriano Reyes Limestone, silica and resins based agglomerate consists of nummulitic limestone with additives improving strength and machinability
ES2187313A1 (en) * 1999-09-01 2003-06-01 Cosentino Sa Fabrication of artificial e.g. decorative stone blocks consists of mixing of liquid resin with liquid pigments and e.g. crushed granite fractions
EP1611992A1 (en) * 2004-05-25 2006-01-04 Tamko Roofing Products Inc. Method of forming a molding surface for a composite shingle mold
BE1016807A3 (en) * 2005-10-13 2007-07-03 Guido Cardinaels Plastic cover piece, e.g. roof covering element, comprises low density layer and high density layer containing visible filler material

Also Published As

Publication number Publication date
GB8423597D0 (en) 1984-10-24
GB2164340B (en) 1988-01-20

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PCNP Patent ceased through non-payment of renewal fee