GB2360039A - Filler compound - Google Patents

Abstract

A compound for use in the repair and filling of structural and/or decorative materials, for example, for use in the restoration of stonework. The compound comprises a settable fluid resin base which is orthopthalic, low exothermic and low styrene in form, and contains fragments of stone material having a volume between 3mm<SP>2</SP> and 0.1mm<SP>2</SP> together with colourant pigments such as earth or polyester pigments. The size of the fragments and colour of the pigments are selected so as to correspond to the appearance, texture and colour of the material under repair. A hardener is included in the compound to set the resin. Also disclosed is the filler compound in kit form.

Description

FILLER COMPOUND The present invention relates to a compound for use in the repair and filing of structural and/or decorative materials, and more particularly, though not exclusively, to such a compound for use in conjunction with the restoration of stonework. In this connection, damage to stonework can result from many factors, such as everyday wear and tear, vandalism, aging and corrosion. In general, in order to repair damage to stonework, e.g. slate, brick and marble, a restorer may be required to carry out cosmetic work, e.g. replace missing surface material with a substitute but may also have to repair structural weaknesses, such as cracks. Filling cracks in stonework can help to improve the outward appearance of the stonework and can also help to prevent the stonework from structurally deteriorating further. The use of resin fillers for this purpose is known in domestic, industrial and commercial applications. Such uses extend to restoration associated with historical buildings, sculptures and architectural structures. In this respect however, such known resin fillers suffer certain problems, particularly when used on stone work where the texture and colour of the stone work under repair are important. In particular, known resins fillers are limited in colour to a blue/white or straw colour. Hence, when used on stone work not of these precise colours, the repaired area stands out undesirably. Further, known resin fillers are very smooth in texture such that again where the stone work under repair has a different texture, the area repaired will be obvious. Moreover, as the repair itself ages, any coating applied to the filler in an attempt to camouflage its existence will wear away thus revealing the repair. Hence, in the vast majority of stonework repairs, existing resin fillers can provide a degree of structural repair but can not provide a finish that resembles the material to which they are applied in either visual appearance or texture. Further, existing resin fillers provide no means for the user of varying their visual or textural characteristics in order to resemble, more closely, the material to which they are applied. As a result, existing resin fillers applied to materials used for structural and/or decorative purposes detract from the visual appearance and textural quality of the item under repair. An object of the present invention is therefore to provide a filler compound which seeks to overcome such problems of known fillers. According to a first aspect of the present invention there is provided a compound intended to resemble, in texture and/or appearance, a material used for structural and/or decorative purposes; the compound comprising a settable fluid resin containing fragments of a stone material. The use of such fragments affords the compound characteristics enhancing its appearance and texture in relation to the material under repair. Preferably, the compound further comprises a colourant pigment. Colourant pigments can be used to further enhance the appearance of the compound. In preferred embodiments, the resin is orthopthalic, low exothermic and low styrene (Lloyds approved BS 3532 1962 Type A). Such a resin has been found to be compatible with the fragments being used. Conveniently, the fragments have a volume falling between 3mm3 and O.lmm3. Varying the size of fragment thereby allows the texture of the said material to be matched more closely. Preferably, the ratio of said fragments to said resin is 0.5 - 4.0 parts fragment to 1.0 part resin. In preferred embodiments, the fragments are selected from any of the following stone materials or combination thereof; slate, granite, marble, brick. Clearly the fragments can be mixed to more accurately resemble the original work. Having the fragments dispersed throughout the compound affords the compound a three-dimensional quality, giving it depth of texture and colour in appearance, but also allowing it to wear realistically with the original work. Conveniently, said colourant pigment may comprise earth pigment and/or polyester pigment enhancing the natural appearance of the compound. Preferably, said resin is settable in response to the addition thereto of a hardener. The experienced user can therefore vary the hardener to suit the requirements of the work being restored. In preferred embodiments, said hardener comprises Butanox M50 - Methyl Ethyl Ketone Peroxide<B>33%</B> in Dimethyl Phthalate. According to a further aspect of the present invention there is provided a compound intended to resemble, in texture and/or appearance a material used for structural and/or decorative purposes; the compound comprising a settable fluid resin containing crushed natural stone. According to a further aspect of the present invention there is provided a kit for use in the repair of stonework, the kit comprising the components:- a resin; a hardener; crushed stone fragments; a user being able to mix the components to form a match with the stonework being repaired. Such a kit provides the individual user with a means for effecting a tailored repair on site. Preferably, the kit further comprises a plurality of different stone fragments and a plurality of different colour pigments. In order that the invention may be clearly understood and readily carried into effect, one embodiment thereof will now be described, by way of example only. The present invention comprises a resin compound used for the repair and filing of structural and/or decorative materials, and more particularly, though not exclusively, to such a compound for use in conjunction with the restoration of stonework. Such stonework may typically be part of a marble fireplace or of a stone sculpture. In such works, the appearance, including the colour and texture of the original work are distinctive. To date, repairs of such works has involved the use of designated resins which are limited in their colour and texture such that in the majority of cases a repair that is sympathetic to the original work is not possible. With the present invention, the inventors have appreciated that by adding fragments matching or closely resembling the said material to a resin base, a much more effective repair can be achieved. The use of such fragments allows the repair material to be tailored for a specific work, such that for example where the original material is of a coarse finish, large fragments of material can be added. In general however, the fragments have a volume falling between 3mm3 and O.lmm3 and the ratio of said fragments to said resin is 0.5 - 4.0 parts fragment to 1.0 part resin. In order to mask any colour of the visible resin from the eye, earth and/or polyester pigment can be added to the resin. The resin itself is preferably an orthopthalic, low exothermic and low styrene form. In use a paste is made up comprising resin together with suitable stone fragments and colour pigments. The consistency of the paste can be matched to the application, so that for example a thick paste can be used on vertical repairs such as sculptures, whereas a more flowable, pourable version can be used for horizontal repairs, such as tiles. To set the compound, a specified amount of hardener is added, the amount can be varied by an experienced user to afford suitable time for working the compound. Solidification of the resin can generally take between approximately 30 minutes and 1 hour. A suitable hardener is Butanox M50 - Methyl Ethyl Ketone Peroxide 33% in Dimethyl Phthalate. A large range of compounds varying in colour and texture can be produced. For example, a range of resins adapted to be used on marble would include a colour range of black marble, green marble and white marble.

The compound is however adapted for repairs and filling of structural and/or decorative materials which includes for example the mending of floor tiles and roof slates. In a further aspect of the invention, a kit is provided so that the user can acquire the components unmixed, and then tailor the repair compound on site. The kit can in this respect comprise the components of a resin, a hardener, a plurality of different crushed stone fragments and a plurality of different colour pigments. In this way the user has the means for effecting a tailored sympathetic repair.

Claims (14)

1. <U>Claims</U> 1. A compound intended to resemble, in texture and/or appearance, a material used for structural and/or decorative purposes; the compound comprising a settable fluid resin containing fragments of a stone material.
2. 2. A compound according to claim 1, further comprising a colourant pigment.
3. 3. A compound according to either claim 1 or 2, wherein the said resin is orthopthalic, low exothermic and low styrene.
4. 4. A compound according to any preceding claim, wherein the fragments have a volume falling between 3mm3 and O.lmm3.
5. 5. A compound according to any preceding claim, wherein the ratio of said fragments to said resin is 0.5 - 4.0 parts fragment to 1.0 part resin.
6. 6. A compound according to any preceding claim, wherein the fragments are selected from any of the following stone materials or combination thereof; slate, granite, marble, brick.
7. 7. A compound according to claim 2, wherein said colourant pigment may comprise earth pigment and/or polyester pigment.
8. 8. A compound according to any preceding claim, wherein said resin is settable in response to the addition thereto of a hardener.
9. 9. A compound according to claim 8, wherein said hardener comprises Butanox M50 - Methyl Ethyl Ketone Peroxide 330 in Dimethyl Phthalate.
10. 10. A compound intended to resemble, in texture and/or appearance a material used for structural and/or decorative purposes; the compound comprising a settable fluid resin containing crushed natural stone.
11. 11. A kit for use in the repair of stonework, the kit comprising the components:- a resin; a hardener; crushed stone fragments; a user being able to mix the components to form a match the stonework being repaired.
12. 12. A kit according to claim 11, further comprising colour pigment.
13. 13. A kit according to claim 11 or 12, wherein the kit comprises a plurality of different stone fragments.
14. 14. A kit according to claim 12, wherein the kit comprises a plurality of different colour pigments.