ITBN20100001A1

ITBN20100001A1 - "PROCESS OF PRODUCTION OF WASHBASINS AND SINKS IN UNIQUE PIECES WITHOUT JUNCTIONS, IN QUARTZ AGGLOMERATE / RESIN WITH HIGH PHYSICAL-MECHANICAL AND CHEMICAL RESISTANCE"

Info

Publication number: ITBN20100001A1
Application number: IT000001A
Authority: IT
Inventors: Ferdinando Possemato
Original assignee: Ch Roma Surface S R L
Priority date: 2010-01-15
Filing date: 2010-01-15
Publication date: 2011-07-15

Description

DESCRIZIONE del brevetto per invenzione industriale avente titolo: ?Processo di produzione di lavabi e lavelli in pezzi unici senza giunzioni, in agglomerato di quarzo/resina ad alta resistenza fisico-meccanica e chimica?a nome di: DESCRIPTION of the patent for industrial invention entitled:? Production process of washbasins and sinks in single pieces without joints, in quartz / resin agglomerate with high physical-mechanical and chemical resistance? In the name of:

Testo della descrizione Description text

Questa invenzione ha per oggetto il processo di produzione di lavabi e lavelli in pezzi unici senza giunzioni, in agglomerato di quarzo/resina ad alta resistenza fisicomeccanica e chimica. I processi di produzione e la composizione degli agglomerati di quarzo/resina permettono, attualmente, la sola fabbricazione di lastre piane destinate ad applicazioni di pavimenti, rivestimenti e piani cucina/bagno. La gamma di prodotti complessi (lavabi e lavelli) presenti sul mercato ? rappresentata da materiali di scarsa durabilit? e resistenza (acciaio inox, ceramica e materiali compositi con elevate quantit? di polimeri, es. Corian). I lavelli e lavabi in quarzo/resina, attualmente in commercio, sono rappresentati unicamente da elementi tagliati da lastre piane ed incollati mediante opportuni sigillanti. Ci? limita l?offerta alle sole forme quadrate o rettangolari con angoli vivi, che facilmente trattengono acqua e sporco, favorendo lo sviluppo di muffe e batteri nelle zone di incollaggio, oltre a non garantire la perfetta tenuta all?acqua. L?innovazione di prodotto e di processo, oggetto del brevetto, permette di ampliare la gamma di articoli offerti, producendo elementi complessi senza giunzioni (lavabi, lavelli, piatti doccia, vasche e etc.) di diverse forme e dimensioni, aventi composizione in agglomerato di quarzo/resina con elevate resistenze fisico-meccaniche e chimiche, perfettamente abbinabili per finitura, estetica e colore anche alle lastre piane sopra indicate. This invention relates to the production process of washbasins and sinks in single pieces without joints, in quartz / resin agglomerate with high physicomechanical and chemical resistance. The production processes and the composition of the quartz / resin agglomerates currently only allow the manufacture of flat sheets intended for floor, wall and kitchen / bathroom applications. The range of complex products (washbasins and sinks) on the market? represented by materials of poor durability? and resistance (stainless steel, ceramic and composite materials with high quantities of polymers, eg Corian). The quartz / resin sinks and washbasins currently on the market are represented solely by elements cut from flat slabs and glued using suitable sealants. There? it limits the offer only to square or rectangular shapes with sharp corners, which easily retain water and dirt, favoring the development of mold and bacteria in the bonding areas, as well as not guaranteeing perfect water tightness. The product and process innovation, object of the patent, allows to expand the range of items offered, producing complex elements without joints (washbasins, sinks, shower trays, bathtubs and etc.) of different shapes and sizes, having an agglomerate composition of quartz / resin with high physical-mechanical and chemical resistance, perfectly combinable in terms of finish, aesthetics and color even with the flat sheets indicated above.

Composizione Composition

La miscela, innovativa per tipologia e quantit? di polimero, si caratterizza per inerti/granulati silicei di quarzo bianco, trasparente o colorato di granulometria variabile tra 0,005 e 20,000 mm miscelati opportunamente con polimeri di diversa natura, tipo resine bicomponenti epossidiche, resine poliesteri ortoftaliche o isoneopentiliche o diciclopentadiene , resine vinilesteri, resine acriliche, resine poliuretane, eie. e pigmenti colorati organici o inorganici in polvere o dispersi in veicoli liquidi. Oltre alle cariche di quarzo ? possibile inserire inerti di varia natura e composizione mineralogica ( es: granito, marmo, feldspato, porfido, onici, basalti, pietre laviche, tufi, argille, inerti metallici, scaglie poliesteri, legno, plastiche, vetro, specchi, glitters). Il rapporto tra i componenti, quarzo/polimero, ? di circa 80/20 e la scelta del granulato o del polimero ? definita sulla base della destinazione d?uso del prodotto finale. Per le resine poliesteri, sopra elencate, sono fondamentali gli additivi di reticolazione a freddo tra cui l?ottoato di cobalto come accelerante e il metiletilchetoneperossido come catalizzatore a basse temperature. The blend, innovative in type and quantity? of polymer, it is characterized by inert / siliceous granulates of white, transparent or colored quartz with granulometry varying between 0.005 and 20,000 mm suitably mixed with polymers of different nature, such as two-component epoxy resins, orthophthalic or isoneopentyl polyester resins or dicyclopentadiene, vinylester resins, resins acrylics, polyurethane resins, eie. and organic or inorganic colored pigments in powder form or dispersed in liquid vehicles. In addition to the quartz fillers? It is possible to insert aggregates of various kinds and mineralogical compositions (eg: granite, marble, feldspar, porphyry, onyx, basalts, lava stones, tuffs, clays, metal aggregates, polyester flakes, wood, plastics, glass, mirrors, glitters). The relationship between the components, quartz / polymer,? about 80/20 and the choice of granulate or polymer? defined on the basis of the intended use of the final product. For the polyester resins listed above, cold crosslinking additives are essential, including cobalt octoate as an accelerator and methylethylketone peroxide as a catalyst at low temperatures.

Processo Process

Una volta pesata e preparata la miscela di ingredienti, questa viene immersa in un miscelatore continuo o discontinuo (dipendente dal numero di elementi da produrre). La composizione della girante di mescolazione ? particolarmente importante per la resistenza all?usura e all?abrasione del quarzo e pertanto la vite di miscelazione del miscelatore continuo dovr? essere realizzata con rivestimento in allumina mentre quella del miscelatore discontinuo dovr? essere cromata cos? come la bacinella contenente la miscela. Intanto si preparano gli stampi e i controstampi ( in vetroresina, in silicone, in ferro, in alluminio o in legno) trattandoli con opportuni distaccanti tipo cere o siliconici. Ogni elemento di una specifica geometria possiede il suo stampo ed il suo controstampo realizzati, nella maggior parte dei casi, in vetroresina avendo cura di utilizzare fibra di carbonio bi o tri-assiale e resine epossidiche bi-componenti che meglio garantiscono la stabilit? dimensionale nella fase di reticolazione del pezzo nello stampo. Si miscela sottovuoto (grado di vuoto variabile tra -0,8 e -1,0 bar) rimpasto per un tempo variabile in funzione degli additivi presenti in miscela (reagenti dosati al fine di ottenere la catalisi, indurimento, del pezzo finale). La miscela risultante viene introdotta nello stampo da un?apertura posizionata su un lato (pu? essere un lato qualsiasi dello stampo o pi? lati per favorire il perfetto riempimento). Durante la colata pu? essere o non applicata una vibrazione per facilitare la scorrevolezza dell?impasto nello stampo. Una volta riempito lo stampo con l?impasto vi si applica il vuoto assoluto e quindi il degassaggio (grado di vuoto variabile tra -0,8 e -1,0 bar), con l?ausilio di una pompa da vuoto e con un coperchio<1 >a tenuta ermetica posto sull?apertura dello stampo predisposto all?attacco del tubo per il degassaggio mediante un attacco ad innesto rapido. Durante l?aspirazione delFaria presente nell?impasto, e dunque nello stampo, viene eseguita la vibrazione posizionando lo stampo su una piastra/tavola vibrante. L?indurimento del pezzo colato avviene a temperatura ambiente grazie agli additivi/reagenti presenti nella formulazione in un tempo variabile tra i 5 minuti e le 10 ore. Una volta avvenuto l?indurimento si sforma il pezzo con un sistema di estrazione a barre filettate<2 >poste tra stampo e controstampo. Estratto il pezzo, viene catalizzato in un apposito forno di essiccazione a temperature variabili tra 60 e 200 ?C (in funzione della geometria e della quantit? di additivi/reagenti presenti in formulazione). Terminata la catalisi e riportando il pezzo a temperatura ambiente, questo pu? essere rifinito con opportune macchine levigatrici. Le fasi del processo sono descritte nella fig.l dell? Allegato Disegno. Once the mixture of ingredients has been weighed and prepared, it is immersed in a continuous or discontinuous mixer (depending on the number of elements to be produced). The composition of the mixing impeller? particularly important for the resistance to wear and abrasion of the quartz and therefore the mixing screw of the continuous mixer will have to? be made with alumina coating while that of the discontinuous mixer will have to? be chromed cos? such as the basin containing the mixture. In the meantime, the molds and counter-molds (in fiberglass, silicone, iron, aluminum or wood) are prepared by treating them with suitable release agents such as waxes or silicones. Each element of a specific geometry has its own mold and counter-mold made, in most cases, in fiberglass, taking care to use bi or tri-axial carbon fiber and bi-component epoxy resins that best guarantee stability. dimensional in the crosslinking phase of the piece in the mold. It is mixed under vacuum (degree of vacuum variable between -0.8 and -1.0 bar) and reshuffled for a variable time according to the additives present in the mixture (reagents dosed in order to obtain catalysis, hardening, of the final piece). The resulting mixture is introduced into the mold from an opening positioned on one side (it can be any side of the mold or multiple sides to facilitate perfect filling). During the casting can? be or not a vibration applied to facilitate the smoothness of the dough in the mold. Once the mold has been filled with the mixture, an absolute vacuum is applied and then degassing (degree of vacuum variable between -0.8 and -1.0 bar), with the help of a vacuum pump and with a lid <1> hermetic seal placed on the opening of the mold predisposed to the connection of the degassing tube by means of a quick coupling. During the suction of the air present in the dough, and therefore in the mold, the vibration is performed by positioning the mold on a vibrating plate / table. The hardening of the cast part takes place at room temperature thanks to the additives / reagents present in the formulation in a time varying between 5 minutes and 10 hours. Once hardening has taken place, the piece is demoulded with an extraction system with threaded bars <2> placed between the mold and counter-mold. Once the piece is extracted, it is catalysed in a special drying oven at temperatures ranging from 60 to 200 ° C (depending on the geometry and the quantity of additives / reagents present in the formulation). After the catalysis and bringing the piece back to room temperature, this can? be finished with suitable sanding machines. The phases of the process are described in fig. Attachment Drawing.

Claims

Claims Patent claims for industrial invention entitled:? Production process of washbasins and sinks in single pieces without joints, in quartz / resin agglomerate with high physical-mechanical and chemical resistance List 1. Composition of the mixture for complex shapes (for washbasins, sinks, shower trays, etc.)? The mixture ? consisting of an iso neopentyl polyester resin with the addition of acrylic monomer to increase the final chemical resistance, with low viscosity? and media reactivity? in order to guarantee the necessary fluidity? to the final mixture and a combination of appropriately selected quartz granules in certain granulometric ranges (from 0.005 mm to 20.000 mm) dosed in such a way as to minimize the quantity? voids between the different particles (analysis of the quantities and dosages with methods of Bolomey, Fuller and Empty / Full). The reagent additives for the polyester resin guarantee the hardening at room temperature of the piece cast in the mold. These are represented by a cobalt octate (setting accelerator) and a methylethyl ketone peroxide (catalyst at low temperatures) as well as? from an adhesion promoter additive between organic and inorganic substances based on Silanes. The color of the mixture is obtained by means of organic or inorganic pigments present in the form of micronic powders or carried by liquids and dispersed in the mixture in order to obtain a final isotropy.

2. Mixing under vacuum: the additive resin, the aggregates and the selected pigments are mixed under vacuum (continuous or discontinuous mixer) in order to obtain a compact and air-free composite. There? guarantees a non-porous final product with high mechanical resistance.

3. Combined action of vacuum and vibration on the molds containing the mixture: once the mold has been filled with the above mixture, this is degassed, through a vacuum system, by connecting the lid1 placed on the mold prepared by means of a quick coupling, to a special vacuum pump, and simultaneously vibrated to make it flow better Taria from the mold and then from the mixture.

4. Demoulding system of the hardened piece from the mold: with the help of special threaded bars2, placed between the mold and the counter-mold, a pressure is exerted to be able to detach the mold from the counter-mold and therefore facilitate the extraction of the hardened piece with special extractors present at the bottom of the mold.