LT4085B - Faced board for walls and method for making the same - Google Patents

Abstract

Invention applies to construction and may be used for decorative wall cladding. In the wall cladding panel, sand aggregate and in an aggregate of polyester epoxy binding there are additionally put in calcium carbonate and/or aluminium oxide and glass fibre. The panel surface in addition covered with the decorative grain layer made of fine crushed rock, granite, marble, glass, ceramics, gravel or its mixtures. The decorative grains render the panel's surface some roughness. These may be fine (0-2 mm), average (1-3 mm), large (3-8 mm) or very large with a diameter of more than 8 mm. The wall cladding panel is manufactured in a periodical or continuous manner of the three layers. The lower and middle layers consist of a polyester epoxy, sand with additions and a glass fibre mixture and the upper layer is formed by decorative grains.

Description

The invention relates to construction, namely, decorative decoration of walls, while improving the thermal and acoustic insulation characteristics of rooms and buildings.

There is a known method of manufacturing heat insulating building elements (Polish patent application 271 792 "Method of making a thermal insulating element", IPC ⁴ B 32 B, published January 23, 1989), in which the building element is made of two layers: a substrate consisting of fiberglass fabric or fiberglass and a second layer of mineral or glass wool laid on it. Resin coatings can be mixed with anti-inflammatory and anti-static additives. The building elements made in this way are unobtrusive and are used for insulation of thermal or ventilation pipes.

The closest known technical solution is the British patent application 2 197 673, entitled "Stone imitating natural stone", IPC ⁴ E 04 C 1/40, published 25 May 1988. The construction product consists of a mixture of synthetic resin with a filler. The mold is poured into a mold ready to pour the synthetic resin mixture with the filler and vibrates this mass to remove air bubbles. In the mold, the mass of the product begins to solidify, the part is rolled out and it enters a special furnace, where it hardens at about 120 ° C. The temperature in this furnace is selected so that solvent and monomer residues evaporate from the slab, which, when emitted, causes a slight shattering of the smooth, glossy surface of the workpiece, thereby giving it a matte finish. In the description of the invention, the authors propose one of the possible variants of plate composition, namely (% by weight):

sand with a sand diameter of 0,8 - 1,5 mm

0.4-0.8

0.3-0.6

0,0 - 0,3 sand powder pigment peroxide (initiator of polymerization)

0.5

Polyester resin (with reaction accelerator).

The weight of such finished panel is 10,75 kg per 1 m ² .

The sand blend of various fractions accounts for about 85% of the total weight, which makes this slab fragile and durable. The surface of the panel is smooth, glossy with a matt shade. The matte effect depends on the amount of solvent evaporated and can therefore be very different and uneven. The panels use a mixture of different sand fractions to make the panels. The largest sand is 1.5 mm in diameter, so sand mills are required. In a special furnace completes the polymerization of the resin and evaporates the solvent. Preheating the furnace to the evaporation temperature of the solvent, which is often above +120 ° C, involves additional energy costs. Evaporative organic solvent contaminates the environment and requires additional equipment for solvent vapor collection and recovery.

The object of the invention is the creation of decorative wall panels for durable, non-flammable, impact-resistant, meteorological effects.

Patented sandwich panel with sand filler and polyester resin pen, supplemented with calcium carbonate and / or aluminum oxide and fiberglass, with an extra layer of decorative grain on the panel, and the amount of ingredients in the board is:

sand 20 - 52 calcium carbonate and / or alumina 1-2 glass fiber 14 - 37 decorative grains 19 - 49 polyester resin 14 - 21.

Polyester resin is a separately prepared mixture of unsaturated polyester resin with additives in the following ratios (% by weight):

polyester resin 96.5 - 98.2 Reaction initiator (methylethylketone peroxide) 1.5-2 Reaction accelerator (cobalt naphthenate) 0.3 - 1 Pigment 0.01 - 0.5.

Ornamental grains are granite or marble chippings, glass, ceramics, gravel or mixtures thereof.

These decorative grains are of various fines, namely fine 0-2 mm in diameter, medium fine 1-3 mm in diameter, large in diameter 3-8 mm or very large in diameter over 8 mm.

Addition of calcium carbonate (ground dolomite) and / or aluminum oxide (kaolin) to the sand filler to give the synthetic resin a matte resembling that of a natural stone. Fiberglass is cut into fibers of approximately the same length. This is the panel reinforcing component. In addition, non-combustible fiberglass reduces the flammability of the entire product.

A pigment is added to the polyester resin, the amount and type of which are selected according to the desired coloring effect. For example, iron scraper stains brownish, soot gray.

The top rough layer of the panel consists of decorative grains that give this product its original look and extra strength. Uses a variety of natural building materials, namely, crushed stone, granite, marble, gravel, glass, ceramics and mixtures thereof. These materials are selected according to the desired decorative effect.

Wall finishing panels are used for interior and exterior walls of various buildings, for decoration of individual parts of buildings (balconies, blinds, etc.). Therefore, the surface of the slab is covered with decorative grains of various fines, which determine the roughness of the slab and its mass. If the decorative grains are small (diameter 0-2 mm), the weight of 1 m ^{2 of the} slab is up to 13 kg, if the medium grain (1-3 mm), the weight of 1 m ² is up to 14 kg, if the grains are large (3- 8 mm), 1 m ² up to 19 kg, and panels coated with very large grains (over 8 mm) 1 m ² , weighing between 19 and 27 kg.

The wall finishing panel is formed of three layers, the bottom and middle consisting of a mixture of polyester resin, sand with additives and fiberglass, and the top is made of decorative grains, which are rolled and pressed into the middle layer and retained for 2.5 - 3 hours. . at room temperature and 6 to 8 hours. in a thermostabilization chamber at 65 ± 10 ° C.

The wall finishing board production line (see diagram) consists of polyester resin tanks 1, resin dosing trays 2, glass filament chopping and spreading mechanisms 3, sand and its additives (calcium carbonate, alumina) mixture funnels 4, decorative grain funnel 5, thermostabilization chamber 6, plate edge cutter 7, transverse plate cutting mechanism 8, vibrators 9, plate surface leveling roll 10, stainless steel bar 11, drums 12 and frames 13.

Prepare a polyester resin in a separate room by mixing unsaturated polyester resin with additives - a polymerization reaction initiator (methyl ethyl ketone peroxide), a reaction accelerator (cobalt naphthenate) and a pigment of the desired color or shade. Divide the calculated resin amount into two equal portions and pour the prepared resin into tanks 1. Prepare a sand mixture with calcium carbonate and / or alumina, divide the calculated amount in half and transfer to a sand funnel 4.

There are two ways to produce panels - batch and continuous. During the periodic production from hardboard, the board is molded into a mold, 2700 mm long, 1200 mm wide and 23 mm high. It is lubricated with turpentine wax or other lubricating grease for molds and placed on a stainless steel belt 11. This mold is evenly poured from tank 1 through the dosing tray 2 (50% of the recipe count), from the fiberglass chopping and spreading mechanism 3. half of the calculated amount of fiberglass, through the funnel 4 scatter about half a portion of sand with additives. Vibrator 9 is shaken for a few minutes, allowing sand and fiberglass to sink faster. The other resin 1 then pours the remaining resin through the dosing tray 2 onto the top of the lower layer, spreads the fiberglass by means of the mechanism 3, dispenses the remaining amount of sand through the hopper 4, and distributes the filler through the layer with a vibrator 9. The top layer of the panel is formed by dispensing from the hopper 5 all the calculated amount of decorative grains. Roller 10 presses these grains into the middle layer and flattens the plate surface. The workpiece leaves for 2.5 - 3 hours. at room temperature, the mass solidifies and solidifies. Stainless steel tape feeds the plate into a thermostabilization chamber at 65 ± 10 ° C. Here the plates remain for 6-8 hours. At higher temperatures, the resin hardens faster and the wall finishing board is formed. Removes the board from the mold, cuts the edges 7 and 8 with special knives, turns it on its side and shakes off non-stick decorative grains.

Finished panel dimensions: length 2700 mm, width 1200 mm, height 7 mm. Other shapes or dimensions can also be produced. In the continuous production of the panels, all the materials provided are evenly distributed on the stainless steel strip, forming a continuous strip of the panel, which is then cut into the panels with knives 7 and 8. The finished panels are placed face up on wooden pallets on top of the façade surface, sheets of paper or similar material are placed between the panels, the sheets are covered with polyethylene film, secured with metal or plastic tape.

The following materials may be used in the manufacture of patented wall cladding panels:

1. Unsaturated Polyester Resin, OST 6-05-431-78.

(styrene type ΠΗ-1, ΓΊΗ-2, ΠΗ-3)

2. Finnish "Nešte" S-380 grade resin.

3. Norwegian Norpolk 44-M-85 grade resin.

4. Complex twisted, glass thread - GOST 8325-93.

5. Quartz Sand, GOST 22551-77.

6. Sand, GOST 8736-85.

7. Granite Rubble, GOST 8267-82.

8. Ceramics, TS Liet TSR 1-88.

9. Marble, GOST 22856-77.

10. Glass, GOST 111-78.

U. Glass Break, Liet TSR RST 1098-89.

12. Gravel, GOST 9757-83.

13. Sand and Gravel Mixture, GOST 23735-79.

14. Turpentine Wax, TS 6-15-282-80.

15. Pigments:

ocher, OST 6-10-430-80, iron surfer, GOST 8135-74, s

paint SK-1, SK-2, TS Liet TSR - 88, soot, GOST 7885-77E, gas soot, TS 51-690-75, umber natural, GOST 11826-77 and so on.

16. Methyl ethyl ketone peroxide, TS 6-01-465-80.

17. Cobalt Naphthenate (Accelerator NK-1, NK-2), TS 6-05-1075-76.

18. Dolomite (Calcium Carbonate), OST 1484-82, GOST 25607-83.

19. Kaolin (Alumina), TS 21-25-220-78.

The panels may also be manufactured from materials of the same origin and composition provided by other types or manufacturers.

The technical characteristics and performance of finished wall panels are determined by the following methods:

1. Mass of 1 m ² , - TS 5411146-03-94.

2. Color of the facade surface (visually compared to the reference) - TS 5411146-03-94.

3. Compressive strength and bending resistance of the board - GOST 4648-71.

4. Water Absorbability, Frost Resistance, Loss of Decorative Finishing Grain After Freezing - GOST 7025-91.

5. Plate deflection after 28 days immersion in water - 1 / 13A - 2 grade comforter according to his instructions.

6. Material Fire - Explosion Hazard - GOST 12.0.044-89.

7. Radioactive contamination - Lithuanian Hygiene Norms HN40-1994.

The invention is illustrated by the following examples.

Polyester resin is prepared by mixing 96.9% unsaturated polyester resin ΠΗ-1, 2% methylethylketone peroxide, 1% cobalt naphthenate and about 0.01% pigment (kaolin - white, iron - red - brown, ocher - yellow, or cobalt blue - Light blue color). This resin is divided into two equal parts and loaded into tanks 1.

example. The board is made of 1.8 kg of resin with additives, 4.15 kg of quartz sand, 0.25 kg of calcium carbonate with alumina, 2.0 kg of fiberglass and 4.3 kg of medium finishing grains. ^{For 2} plates.

In Examples 2, 3, 4, 5, 6, 7, 8 and 9, the panel is also manufactured using decorative grains of various sizes and pigments of different grades and colors. The composition of the panels in the various variants is shown in Table 1.

The panels are manufactured periodically. Fibreboard is molded, oiled with turpentine wax, filled in the manner described, and kept in the workshop room for 3 hours, then in a thermostabilization chamber at 60 ° C for 6 hours. the board hardens completely. Turns the finished panels out of shape, shakes off non-stick decorative grains, trims edges and repackages. The size of one lot shall not exceed 600 m ² .

For the evaluation of the properties of the finished panels, 5 panels are taken from each batch for testing and checked for performance. The results of the analyzes are shown in Table 2. Analysis of the results of the tests of the properties of the various panel variants shows that all these panels meet the technical requirements, are highly flammable and do not exceed the level of radioactive contamination.

Hygiene norms permitted in the Republic of Lithuania. Compared to a known finishing panel, the weight of patented panels is significantly lower.

The patented plate has good performance, is resistant to bending and crushing deformation, frost and water, as it withstands at least 75 freezing-heating cycles, so that after 28 days in water the plate deformation does not exceed 1.8 mm / m. These parameters are especially important in the climatic conditions of our country and ensure the durability of the finishing materials. The façade surface of the cladding panels is covered with decorative grains of crushed stone, marble, glass, ceramic, gravel or mixtures thereof, and the polyester resin is painted in white, yellow, brown, gray, greenish, so the buildings with walls or façade covered with these panels . These panels, especially if the gap between the wall and the panel is still filled with thermal insulation material such as "Ekovata", improve the thermal and sound insulation characteristics of the building.

Currently, stone grain technology is used for wall finishing in Lithuania, where a mixture of pebbles and binder is sprayed onto smooth walls of buildings using special sprays. Patented wall cladding panels are easier to use because they can be attached to building walls By various methods, the boards can be stored and used for a long time, and when applying the stone "Stone" it is necessary to have special equipment and ready-to-use mixture.

— R - d

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Wall finish panel formulations for 1 m ² panel

Known, % * 14.5 85.0 1 pigm. * * 0.5 100 Examples 05 without Λ w m Ί V 1 03 9.0 1 1 t 1 θ.θ 1 19.95 5? 17.05 20.8 | 1 17.05 , -1 U3 100 00 without 03 oh i 4.0 | 0.23 O 8.5 1 1 t 8.5 19.63 S5 14.8 20.4 vH 20.4 43.3 100 t- without Λ 2.5 1 « 1 «1 03 Oops 1 1 no 1 t »' o? 14.4 25.9 1 18.4 41.3 100 <0 kg 'Ί Oops 3.8 0.22 2.4 10 1 IO 1 1 13.62 xo 15.4 27.9 <0 17.6 37.5 100 in bC Λ! 00 t-H 4.32 10 oh O 2.6 '-1 « w 1 1 12.07 (N m rH 35.7 | 2.0 21.5 co U3 03 100 TT QC Λί oh 4.0 | o o- oh 'f 1 1 M ¹ t- * 1 16.71 xp 14.4 23.91 IO = Ί kO ' co tH 44.3 100 03 b £ Λ 2.0 4.5 | 0.21 2.9 1 ' 1 1 13.71 S5 o Ί * ' rd 32.81 1.5 no i-1 03 29.9 100 03 without Λ oo rd 4.0 n o 2.5 t- 03 ' t- 03 ' 1 1 1 no 03 35 14.8 32.8 | «3 20.5 30.3 100 οβ Λ 1.8 10 ' > n Ή O 2.0 03 1 4.3 i 1 1 12.5 35 14.4 1 33.2 1 2.0 16.0 34.4 100 Ingredients Polyester resin (with extras) In The Sand | Calcium carbonate and / or aluminum oxide Glass fiber Decorative grains small medium finesse To the big ones (very large Altogether:

- GB Patent 2197673.

* bn • H Pd *

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Φ “H

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Properties of wall cladding panels

Examples ΟΆ 1 O no va & va oh Λ VA A not more than 3 not less than 75 not more than 1.8 highly flammable not more than 370 Bg / kg Known GB patent 2197673 va o5 light Brown O NO * 04 o no * of Va VA VA k i a i flammable no more 370 oo ca light green 28.0 47.0 of VA r- Va VA not much giau 370 r- VT r < yellow O r < 04 Oh r < VA of VA r- VA no more 370 NO 26.0 O NO * xr VA of VA r- oh no more 370 no more 370 va of - va AO * 04 θ NO * VA of VA NO N © ^ 1 u n s no more 370 scT 26.0 ΙΛ NO * o of VA »- » NO ΝΟ _Λ * c r- SO -2 27.0 47.0 04 of VA r- Va NO ~ no more 370 04 Oops of yellow 26.0 va va vi · AA of VA r- no more 370 LO of White O v? 04 46.0 O of VA r- no more 370 Features • if y, 2 m Color Compressive strength, MPa Bending resistance, MPa Water absorption,% Frost resistance, cycles Deformation after soaking in water, mm / m Fire hazard Radioactive contamination substances in Bg / kg

Claims (5)

Definition of the Invention 1. A wall finishing board made of sand filler and polyester resin binder, characterized in that the filler additionally contains calcium carbonate and / or alumina and fiberglass, has an additional layer of decorative grain on the surface of the board and contains by weight the ingredients: sand 20-52, calcium carbonate and / or alumina 1-2, glass fiber 14-37, decorative grains 19-49, polyester resin 14-21. Wall panel according to claim 1, characterized in that the polyester resin is a separately prepared mixture of unsaturated polyester resin with additives in the following ratios (% by weight): unsaturated polyester resin 96.5 - 98.2, reaction initiator (methylethylketone peroxide) 1.5 - 2, reaction accelerator (cobalt naphthenate) 0.3 - 1. pigment 0.01 - 0.5. 3 to 8 mm, or very large with a diameter of more than 8 mm. Wall panel according to claim 1, characterized in that the decorative grains are granite or marble chippings, glass, ceramics, gravel or mixtures thereof. Wall panel according to claims 1 and 3, characterized in that the decorative grains are fine with a diameter of 0-2 mm and medium fine with a diameter of 1-3 mm, coarse with a diameter 5. A method of fabricating a wall finishing board, which is made from a mixture of synthetic resin with filler, characterized in that the board is formed of three layers, the lower and middle of which are composed of a mixture of polyester resin, sand with additives and fiberglass and the upper is made of decorative grains. which are rolled and pressed into the middle layer by a roller, which retains this plate at room temperature of 2.5 - 3 vaL and 6-8 hours. in a thermostabilization chamber at 55-75 ° C.