GB2231881A - Moulded articles of resin-bonded stone particles - Google Patents

Moulded articles of resin-bonded stone particles Download PDF

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Publication number
GB2231881A
GB2231881A GB9008039A GB9008039A GB2231881A GB 2231881 A GB2231881 A GB 2231881A GB 9008039 A GB9008039 A GB 9008039A GB 9008039 A GB9008039 A GB 9008039A GB 2231881 A GB2231881 A GB 2231881A
Authority
GB
United Kingdom
Prior art keywords
resin
product
stone
powdered
weight
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.)
Withdrawn
Application number
GB9008039A
Other versions
GB9008039D0 (en
Inventor
Donald Arthur Barrett
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.)
Glasdon Manufacturing Ltd
Original Assignee
Glasdon Manufacturing 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 Glasdon Manufacturing Ltd filed Critical Glasdon Manufacturing Ltd
Publication of GB9008039D0 publication Critical patent/GB9008039D0/en
Publication of GB2231881A publication Critical patent/GB2231881A/en
Withdrawn legal-status Critical Current

Links

Classifications

    • 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
    • C04B26/10—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
    • C04B26/18—Polyesters; Polycarbonates
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C1/00—Building elements of block or other shape for the construction of parts of buildings
    • E04C1/40—Building elements of block or other shape for the construction of parts of buildings built-up from parts of different materials, e.g. composed of layers of different materials or stones with filling material or with insulating inserts
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/04—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres
    • 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
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/54—Substitutes for natural stone, artistic materials or the like

Landscapes

  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Chemical & Material Sciences (AREA)
  • Structural Engineering (AREA)
  • Civil Engineering (AREA)
  • Ceramic Engineering (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Materials Engineering (AREA)
  • Organic Chemistry (AREA)
  • Compositions Of Macromolecular Compounds (AREA)
  • Macromonomer-Based Addition Polymer (AREA)

Abstract

A moulded article, for example a roofing tile, comprises particles of a natural stone (preferably granite) bonded by means of a cured resin.

Description

MOULDED ARTICLES The present invention relates to the production of moulded articles, particularly (but not necessarily exclusively) for use as roofing tiles for buildings.
It is well established practice to clad the rooves of buildings with slates. However, natural slate is becoming increasingly difficult to obtain and may be too expensive for certain applications.
GB-B-2 041 959 proposes a slate roofing tile which comprises slate particles bonded with a thermosetting resin into a unitary product of the desired shape and size. However, once again the product relies on the use of slate.
According to the present invention there is provided a moulded article which comprises particles of a natural stone bonded by means of a cured resin.
The invention also provides a method of producing a moulded article comprising admixing natural stone particles with a curable resin composition, moulding the mixture to a desired shape, and curing the resin.
Preferably the product comprises 75 to 85% by weight of the powdered stone, most preferably about 80%. The powdered stone may for example have a particle size up to 2mm.
It is preferred that at least 40% (more preferably at least 45% by weight) of the powdered stone contents should be in the form of a dust which passes through a 75 micron (200 mesh) sieve. Such volume fraction is preferred because the particulate stone may be readily formed into a plastic compound by admixture with the synthetic resin.
Depending on the type of stone used, the particle size and particle size fraction can be adjusted to provide for maximum reinforcing effect, maximum density and lowest cost. When correctly formulated the compounded ingredients will flow as a homogeneous mass under the action of heat and pressure and cure to an infusible solid, between matched metal tools into the desired shape.
The preferred stone is granite on account of its relative cheapness and the strength which it imparts to the moulded article.
The granite may for example have a specific gravity of 2.64 and be generally of the following analysis, Silica 70% Alumina 16% Peroxide of iron 2.71% Lime 1.76% Magnesia 1.2% Potash 5.42% Soda 3.07% Other natural stones which could be used include sandstone, limestone, Portland stone and marble.
The curable resin is preferably a thermosetting resin, most preferably a polyester resin. Catalysts and promoters of know types may be incorporated in the resin to facilitate curing.
Most preferably, the moulding is effected by a hot press moulding operation using a closed chamber mould. A suitable temperature range is 120-1250C with a pressure of 80-lOOpsi.
In a preferred embodiment of the invention, a roofing tile is prepared by admixing ca 80% by weight of granite particles with ca 1718% of a polyester resin and a balance of calcium carbonate, catalysts and mould release agent. The mixture is then hot pressed using the aforementioned temperatures and pressures in a closed cavity mould so as to produce a roofing tile of the desired dimensions.

Claims (11)

1. A moulded article which comprises particles of a natural stone bonded by means of a cured resin.
2. A product as claimed in claim 1 comprising 75 to 85% by weight of the powdered stone.
3. A product as claimed in claim 2 comprising about 80% by weight of the powdered stone.
4. A product as claimed in any one of claims 1 to 2 wherein the powdered stone has a maximum particle size of 2mm.
5. A product as claimed in any one of claims 1 to 4 wherein the powdered stone comprises at least 40% by weight of a dust which passes through a 75 micron screen.
6. A product as claimed in any one of claim 1 to 5 wherein the powdered stone comprises granite.
7. A product as claimed in any one of claim 1 to 6 in the form of a roofing tile.
8. A method of producing a moulded article comprising admixing natural stone particles with a curable resin composition, moulding the mixture to a desired shape and curing the resin.
9. A method as claimed in claim 8 wherein the resin is a polyester resin.
10. A method as claimed in claim 8 or 9 wherein the moulding is effected by a hot press moulding operation.
11. A method as claimed in any one of claims 8 to 10 wherein the powdered stone is admixed with the curable resin to form a plastic composition prior to curing.
GB9008039A 1989-04-08 1990-04-09 Moulded articles of resin-bonded stone particles Withdrawn GB2231881A (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GB898907945A GB8907945D0 (en) 1989-04-08 1989-04-08 Moulded articles

Publications (2)

Publication Number Publication Date
GB9008039D0 GB9008039D0 (en) 1990-06-06
GB2231881A true GB2231881A (en) 1990-11-28

Family

ID=10654683

Family Applications (2)

Application Number Title Priority Date Filing Date
GB898907945A Pending GB8907945D0 (en) 1989-04-08 1989-04-08 Moulded articles
GB9008039A Withdrawn GB2231881A (en) 1989-04-08 1990-04-09 Moulded articles of resin-bonded stone particles

Family Applications Before (1)

Application Number Title Priority Date Filing Date
GB898907945A Pending GB8907945D0 (en) 1989-04-08 1989-04-08 Moulded articles

Country Status (1)

Country Link
GB (2) GB8907945D0 (en)

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0626216A1 (en) * 1993-05-28 1994-11-30 Terra Ijssel B.V. Method for working up waste materials
ES2148027A1 (en) * 1997-04-15 2000-10-01 Maquinaria Jumilla S L Building roof stamped steel based construction element includes a fungicidal and fire resistant coating on intermediate epoxy polyester and e.g. marble layers
GB2360039A (en) * 2000-03-07 2001-09-12 Magicmatch Ltd Filler compound
WO2004039564A1 (en) * 2002-10-31 2004-05-13 Eco New Technology Llc Method for manufacturing elements from powders and granules

Citations (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB774674A (en) * 1951-06-20 1957-05-15 Hoechst Ag Manufacture of cold-setting compositions yielding chemically resistant solid masses
GB921965A (en) * 1960-02-23 1963-03-27 Btr Industries Ltd An article of artificial granite or granite substitute
US3278662A (en) * 1965-11-17 1966-10-11 Lee R Mangrum Process for making tile embodying stone particles
GB1244857A (en) * 1967-12-06 1971-09-02 Repla Sa Method for making panels of the artificial stone-type and products so produced
GB1404934A (en) * 1971-07-16 1975-09-03 Zacaroli H L Decorative tiles and methods of making them
GB2052471A (en) * 1979-06-22 1981-01-28 Fijon Ltd Artificial granite
US4299761A (en) * 1979-03-19 1981-11-10 Rohm And Haas Company Polymer concrete compositions, methods of application thereof, and polymerized products thereof
GB2157704A (en) * 1984-02-14 1985-10-30 E H Bradley Building Products Building materials; artificial slate
GB2157673A (en) * 1984-04-19 1985-10-30 Ronald Parry Improvements relating to the manufacture of porous articles
GB2197673A (en) * 1986-11-12 1988-05-25 Harris Frederick Brian Oatway Simulated natural stone panels
EP0292628A2 (en) * 1987-05-25 1988-11-30 Panayiotis Stavrakellis Synthetic wood composition from fruit kernels or shells and/or marble chips

Patent Citations (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB774674A (en) * 1951-06-20 1957-05-15 Hoechst Ag Manufacture of cold-setting compositions yielding chemically resistant solid masses
GB921965A (en) * 1960-02-23 1963-03-27 Btr Industries Ltd An article of artificial granite or granite substitute
US3278662A (en) * 1965-11-17 1966-10-11 Lee R Mangrum Process for making tile embodying stone particles
GB1244857A (en) * 1967-12-06 1971-09-02 Repla Sa Method for making panels of the artificial stone-type and products so produced
GB1404934A (en) * 1971-07-16 1975-09-03 Zacaroli H L Decorative tiles and methods of making them
US4299761A (en) * 1979-03-19 1981-11-10 Rohm And Haas Company Polymer concrete compositions, methods of application thereof, and polymerized products thereof
GB2052471A (en) * 1979-06-22 1981-01-28 Fijon Ltd Artificial granite
GB2157704A (en) * 1984-02-14 1985-10-30 E H Bradley Building Products Building materials; artificial slate
GB2157673A (en) * 1984-04-19 1985-10-30 Ronald Parry Improvements relating to the manufacture of porous articles
GB2197673A (en) * 1986-11-12 1988-05-25 Harris Frederick Brian Oatway Simulated natural stone panels
EP0292628A2 (en) * 1987-05-25 1988-11-30 Panayiotis Stavrakellis Synthetic wood composition from fruit kernels or shells and/or marble chips

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0626216A1 (en) * 1993-05-28 1994-11-30 Terra Ijssel B.V. Method for working up waste materials
US5656674A (en) * 1993-05-28 1997-08-12 Terra Ijssel B.V. Method for working up waste materials
ES2148027A1 (en) * 1997-04-15 2000-10-01 Maquinaria Jumilla S L Building roof stamped steel based construction element includes a fungicidal and fire resistant coating on intermediate epoxy polyester and e.g. marble layers
GB2360039A (en) * 2000-03-07 2001-09-12 Magicmatch Ltd Filler compound
WO2004039564A1 (en) * 2002-10-31 2004-05-13 Eco New Technology Llc Method for manufacturing elements from powders and granules

Also Published As

Publication number Publication date
GB9008039D0 (en) 1990-06-06
GB8907945D0 (en) 1989-05-24

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Legal Events

Date Code Title Description
732 Registration of transactions, instruments or events in the register (sect. 32/1977)
WAP Application withdrawn, taken to be withdrawn or refused ** after publication under section 16(1)