MXPA00006194A - Method of producing a decorative construction material - Google Patents

Abstract

A method of producing a resilient decorative construction material from waste products such as slag granulate or waste glass granulate is taught. A layer of material (10) comprising glass granulate, slag granulate, or sand, or mixtures thereof, is placed in a heat-resistant mold (12). The mold (12) has a top (22), sides (24) and a bottom (20) which is preferably coated on the inner mold surface (18) with a fluid suspension of kaolin (13). The layer is thermally treated, and is initially heated so that a temperature gradient is established throughout the layer, with the first surface (14) having a first temperature no greater than the softening point, and the second surface (16) having a second temperature less than the first temperature. Then further heating is conducted to a temperature sufficient to sinter the layer, and also to reverse the temperature gradient throughout the layer, so that the first surface (14) has a lower temperature than the second surface (16). The layer is maintained at temperature and then cooled annealed to produce the final product.

Description

P- METHOD TO PRODUCE A DECORATIVE CONSTRUCTION MATERIAL FIELD OF THE INVENTION The invention relates generally to a method for producing a decorative building material and more specifically, to a method for producing a decorative building material from residual glass granulate, slag granulate, sand or combinations thereof.

BACKGROUND OF THE INVENTION Residual glass, especially post-consumer residual glass, has become problematic in today's society. Many methods are known for recycling waste glass, including grinding glass in particles, followed by the fusion or sintering of the glass particles into new glass objects, including building materials, such as glass or tiles. However, to use the residual glass for such purposes, it is necessary to separate the glass from the plastic, paper and other materials with which the residual glass is mixed. Frequently, one of the most expensive and difficult steps in the recycling process of such waste glass is to clean the glass and remove all the plastic, paper and other residual glass contaminants before recycling. The presence of residual paper can be especially problematic due to the combustion of such paper during the thermal processing of the glass in construction material such as a tile, it can create bubbles, which rise towards the surface of the construction material that is being produced , resulting in a more superior surface containing defects in the form of bubbles or pores. Such defects in the resulting construction material make them unsuitable for many applications, where the appearance of the construction material is paramount. There are several types of equipment known in the art that can separate the glass material from most of the metal, plastic and paper during the processing and grinding of the residual glass for use. ' Inevitably, however, some of these residual materials remain in the crushed glass. There remains a need to be able to produce a building material from waste glass, where the waste glass is contaminated with paper, plastic and other contaminants, which results in a building material having an external surface substantially free of defects, so that the construction material is suitable for decorative uses. In addition, there is a need to produce a building material from waste glass or other industrial waste material, such as slag having sufficient strength and durability to be used in a broad spectrum of applications including exteriors and building floors.

BRIEF DESCRIPTION OF THE INVENTION According to the invention, there is provided a method for producing a construction material comprising glass granulate, together with optional ingredients including scoria granulate, sand and mixtures thereof. In one embodiment, the present invention provides a method for producing a decorative building material for interior and exterior applications, comprising distributing a layer of material in a heat-resistant mold, the layer having a first surface in contact with the mold and a second exposed surface. The layer comprises glass granulate and may include at least one material selected from the group consisting of slag granules, sand and mixtures thereof. The mold and the layer are placed in an oven. The layer is then initially heated from the bottom of the mold, to establish a temperature gradient across the layer, with the first surface of the layer having a temperature no higher than the softening temperature of the material used, and the second surface having a second lower temperature than the first temperature. These temperatures are maintained for a period of time and then the layer is further heated. The layer is then heated to a higher temperature sufficient to sinter the material of the layer. During this portion of the heating process, the temperature gradient across the layer is reversed, so that the first surface has a third temperature and the second surface has a fourth temperature greater than the third temperature. The third and fourth temperatures are maintained for a sufficient time to sinter the material in a construction material having a second surface substantially free of defects, followed by cooling and annealing of the construction material. The construction material is then removed from the mold, and optionally it can be sanded and polished. Additionally, the invention comprises a method for manufacturing a construction material comprising two layers. Each layer comprises glass granulate and may include at least one material selected from the group consisting of slag granulate, sand and mixtures thereof. A first layer of the material is placed in a heat resistant mold, the first layer has a first surface in contact with the mold, and a second surface exposed. A second layer of material, having a first surface and a second surface, is placed directly on the first layer, so that the first surface of the second layer covers the second surface of the first layer. The layers are then heated inside the mold, so that a temperature gradient is established through the layers with the first surface of the first layer having a first temperature, no higher than the softening temperature of the material comprising the first layer, and the • Second surface of the second layer having a second temperature, which is less than the first temperature. These temperatures are therefore maintained for a period of time and the layers are further heated. The layers are then further heated to a temperature sufficient to sinter the first and second layers. During this portion of the heating process, the temperature gradient across the layers is reversed, so that the • first surface of the first layer has a third temperature and the second surface of the second layer has a fourth temperature, greater than the third temperature. The third and fourth temperatures are maintained for a period of time sufficient to sinter the material in a construction material having a second surface substantially free of defects, followed by cooling and annealing of construction material. The construction material is then removed from the mold, and optionally it can be sanded and polished. The present invention further comprises a method for manufacturing a construction material comprising three layers. Each layer comprises glass granulate and may include at least one material selected from the group consisting of slag granulate, sand and mixtures thereof. A first layer of the material is placed in a heat resistant mold, the first layer has a first • 10 surface in contact with the mold, and a second exposed surface. A second layer of material, having a first surface and a second surface, is placed directly on the first layer so that the first surface of the second layer covers the second surface of the first layer.

A third layer of material, having first and second surfaces, is placed directly on the second layer, so that the first surface of the third layer covers the second layer. $ second surface of the second layer. The layers are then heated inside the mold, so that a temperature environment through the layers with the first surface of the first layer having a first temperature no greater than the softening temperature of the material comprising the first layer, and the second surface of the third layer having a second temperature, which is less than the first temperature.

These temperatures are therefore maintained for a period of time and the layers are further heated. The layers are then further heated to a temperature sufficient to sinter the three layers. During this portion of the heating process, the temperature gradient across the layers is reversed, so that the first surface of the first layer has a third temperature and the second surface of the third layer has a fourth temperature, greater than The third t 10 temperature. The third and fourth temperatures are maintained for a period of time sufficient to sinter the material in a construction material having a second surface substantially free of defects, followed by cooling and annealing of the construction material. He construction material is then removed from the mold, and optionally it can be sanded and polished. In another embodiment of the present invention, • produces a multi-layer construction material, where one or more of the layers comprises one or more materials selected from the group consisting of slag granules, sand and mixtures thereof, including the presence of glass granules. At least one layer "of the multilayer construction material comprises glass granulate, preferably, but not necessarily, the last layer placed inside the mold. The glass granulate may not be present in the remaining layers of the multilayer construction material of this embodiment. In another embodiment of the present invention, §HW provides a method where the step of cooling and annealing comprises cooling the layers to a fifth temperature, which is equal to or lower than the higher annealing temperature, and maintaining this fifth temperature to dissipate the temperature gradient across the layers. layers to allow all layers to approximately reach the same temperature. This is followed by additional cooling of the layers to a sixth temperature at a rate of about 0.5-4.0 ° C per minute, until a temperature of about 10-20 ° C is reached below the lower annealing temperature, and finally cooling the layers to an ambient temperature at a rate of about 5-50 ° C per minute. In another embodiment of the present invention, one or more layers of the above building materials will initially include a colorant and / or a binder. before the heat treatment.

BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is a cross section of a heat resistant mold containing a single layer construction material 25 according to the present invention.

Figure 2 is a graph of the temperature regimes of a first surface and a second surface of the construction material shown in Figure 1. Figure 3 is a cross section of a heat-resistant mold and a two-layer construction material. made in accordance with the present invention. Figure 4 is a cross section of a heat-resistant mold of a three-layer building material made in accordance with the present invention. Figure 5 is a cross section of a laboratory electric furnace used to produce a construction material in accordance with the present invention. Figure 6 is a schematic design of an automated gas rolling kiln used to produce a construction material according to. the present invention.

DETAILED DESCRIPTION OF THE INVENTION In the following description, a number of terms were used exhaustively. Definitions are provided herein to facilitate the understanding of the invention. Binding Agent: A material that helps to prevent gas bubbles from forming in a tile during the heat treatment and rising to the surface, helping to prevent the appearance of defects in the surface of the resulting tile. Typical binding agents include, but are not limited to inorganic agents such as Na2Si03, K2Si03, and Al203.2Si02 (Kaolin), and organic agents such as sodium carboxymethylcellulose. Coloring: Any metal oxide that is typically used in the ceramic or glass industry for the coloring of glass and ceramic materials. The metals for producing the oxides can be of various oxidation states and typically include, but are not limited to, oxides of: Fe, Al, Si, Zn, Ca, Mg, Co, Cr, Zr, Pb, Ni, Mn, Mo, Cu, Sn, V, and Sb. Glass Granulate: Crushed glass particles, which include glass particles manufactured from waste glass or dirty glass, that is, glass collected from industrial and / or residential waste containing impurities such as plastic particles, paper, metals, etc. Any pure material, in pieces or residual that includes primary glass or glass particles, are within the definition of this term. Key points or temperatures: The lower annealing temperature, the softening temperature, and the higher annealing temperature of the glass granulate in a layer other than the construction material.

Lower Annealing Temperature: The temperature at which a glass granulate has the viscosity of 1014'5 poise. Slag Granulate: Articles of the non-metallic waste product resulting from the interaction of the flux and impurities in the melting or melting of metals. Softening Temperature: The temperature at which a glass granulate has the viscosity of 107'65 poise. Higher Annealing Temperature: The temperature at which a glass granulate has the viscosity of 1013 poise. In practice, this temperature will not vary much, since the majority of the residual glass consists of glass of containers (bottles) or plane (windows), which is a glass of soda and lime whose composition does not vary much between the different countries. Some special glasses with higher or lower annealing temperatures may be present in the residual glass material, but the amount of such glasses is generally very small, since such special glass is usually collected separately. The object of the invention is a construction material, comprising one or more distinct layers, each layer being made of one or more materials selected from the group consisting of glass granulate, slag granulate, sand and mixtures thereof. Such building materials can be used as internal or external tiles for buildings, industrial or residential areas, • sanitary facilities, or for floors thereof. The preferred material for each layer of the building material is glass particles, preferably residual glass particles, which include small amounts of metal, plastic, paper, adhesives or other contaminants found in the residual glass that have not have been separated during processing of the residual glass into residual glass particles via grinding or other methods well known in the art. Using the methods of the present invention, it has been surprisingly and unexpectedly discovered that it is not necessary to remove the paper, adhesive material, and other impurities from the residual glass before its use in the formation of a building material, thus eliminating expensive cleaning steps • and that they consume time in the preparation of the residual glass to use it in a construction material. The glass used in the present invention only needs to be ground to uniform particle sizes, without an exhaustive pre-cleaning, generally having the size of less than 5 mm, preferably having an average size of 2mm or less. The glass can be colored glass or transparent glass. Typically, the chemical composition of the slag granulate is: Si02 = 30-62%, Al2C3 = 6-25%, FeO = 0.3-10%, CaO = 1-50%, and MgO = 1-10%. In a preferred embodiment, the construction material will be prepared to • start from a combination of glass granulate and slag granulate 5 and be free of sand. In another preferred embodiment, the construction material will be prepared from glass granulate and will be free of slag granules and sand. Since they can be used multiple types of glass granulation in any particular layer, it may be necessary to calculate the viscosity for particular combinations of glass to make the appropriate temperature determinations. In addition, multi-layer construction materials may comprise two or more layers which contain glass granules that have different key points for each layer. In such cases, the temperatures used during manufacturing • preferably they will consist of using the lowest of the key points or temperatures for the multiple layers. Without However, in those cases where there are multiple key points, a longer pause will be required at each of the lower of the lower annealing temperatures and the higher annealing temperatures, typically up to 50% more in time, during processing to ensure a product free of defects. Additionally, if there are multiple temperatures for such upper and lower annealing temperatures, it is possible to heat the layers to each of the different upper and lower annealing temperatures. • for each layer in the construction material, followed by a suitable dwell time at the specified upper and lower annealing temperature. It is also possible to use the highest of each of the softening temperatures if there are multiple softening temperatures for multi-layer building materials, comprising two or more layers containing a glass granulate having different softening temperatures. If the higher such temperature is used, the rest time or pause time at each of these temperatures will be less if the lower softening temperatures are used.

Finally, a combination can be used, using the highest of some key temperatures, the lowest of other key temperatures and / or multiple key temperatures and • pauses of them. In a preferred embodiment, the material of The construction will be a single layer comprising 25-100% by weight of glass granulate, 0-40% by weight of slag granulate; and 0-35% by weight of sand. The quantities of each material will vary depending on the selections of glass granulate, slag granulate, and sand. used. In a preferred embodiment of a layer, the construction material will have a thickness of about 5-25 mm and a preferred thickness of about 12 mm. In a two-layer building material made according to the method of the present invention, a preferred embodiment will comprise a first layer comprising glass granulate and optionally may include slag granulate, sand and mixtures thereof. The first layer will preferably be 25-100% eh weight of glass granulate, 0-40% by weight of slag granulate and 0-35% by weight of sand. The second layer in the preferred embodiment will comprise glass granulate, up to the exclusion of slag and sand granules. In the preferred embodiment, the first layer will have a thickness of 0-33 mm, preferably 12 mm and the second layer will have a thickness of 1-5 mm, preferably 3 mm. Preferably, the second layer will not comprise more than 10-25% of the total thickness of the construction material. In another preferred embodiment, the construction material will comprise two layers, with the first layer comprising sand, slag granulate or mixtures thereof, and the second layer comprising glass granulate. The second layer may additionally comprise sand, slag granulate, or mixtures thereof. In another embodiment, the construction material will comprise three layers. In a preferred three-layer embodiment, the first and second layers will comprise glass granules and additionally may include at least one material selected from the group consisting of slag granules, sand and mixtures thereof, while the third layer will comprise granules of glass and will exclude the presence of slag and sand granules. In the preferred embodiment, the first layer will have a thickness of 1-6 mm, preferably 2 mm, the second layer will have a thickness of 3-30 mm and preferably 15 mm and the third layer will have a thickness of 1-6 mm, preferably 3 mm. In the preferred embodiment, the first and third layers will each comprise no more than 10-30% of the total thickness of the building material. In another preferred three layer embodiment, one or both of the first two layers will comprise sand, slag granulate, or mixtures thereof, and will exclude the presence of glass granulate. One of the first two layers may contain glass granules. The third layer will comprise glass granulate, and may additionally comprise sand, slag granulate or mixtures thereof. The construction material may also contain optional ingredients, including one or more colorants. The addition of various dyes to the construction material will allow the production of construction materials of various colors, which can simulate various natural or artificial stones. The dyes are typically mixed with the residual glass particles after grinding the residual glass into residual glass particles. The amount of the dyes is preferably 0.01-10% of the total weight of the construction material. The amount of colorant depends not only on the intensity of the desired color but also on the size of the glass granulate, slag granulate or sand particles used. The smaller the size of the granulate / particle used, the smaller the amount of dye necessary to produce a given level of coloring intensity. Typically, the dyes are a very fine powder with a particle size in the range of about 1.0-5.0 μm. Additionally, a binder can be added in addition to or in place of one or more colorants. The binder is added in an amount of about 0-15% by weight of the building material, particularly about 5%. The addition of the binder can be effected to any one or more of the layers. The presence of the binder within the construction material prevents the formation of gas bubbles in the heat treatment construction material and that rise to the surface, thus helping to prevent appearance defects on the external surface of the resulting construction material. In addition, binding agents such as Na2Si03 or K2Si03 can also be used for colored glass particles. The use of the binder is particularly useful when the particle size of the granulate, preferably glass granulate, is greater than about 1 mm, thus making it almost impossible to obtain a homogeneous mixture of larger glass particles with the dyes finely ground very small; however, one or more binding agents can be used with granules of any size, including those of 1 mm or smaller. The binder is added to the material for each layer before packing the material in the mold. The final layer placed inside the heat-resistant mold is the outer layer. Different designs can be made within this outer layer. To produce different designs, glass granules of various colors are used. The coloration of this granulate can be provided by various means known in the art. First, a granulate of fine glass powder is mixed with any granular pigment well known in the art, together with a binder and solvent, such as water, and the materials are mixed, homogenized and extruded. This material is then dried and crushed to the colored granules of appropriate size. A further method comprises mixing the glass granulate together with any dye known in the art and a binder, without the use of a solvent, extrusion or drying. Finally, the colored granulate can be produced using a high temperature oven, only • with glass granulate and without colorant without the use of 5 solvents or binding agents. In the present invention, the materials are packaged in a heat resistant mold. The heat-resistant mold is made in various ways, including in the form of a plate or cylinder. The plate-shaped mold can have a • 10 flat, concave or convex surface. The heat-resistant mold is preferably made of ceramic or metallic material. The heat-resistant mold generally has the same or a lower coefficient of thermal expansion than in the material used to form the building material.

The internal surface of the mold can optionally be coated with a fluid solution of kaolin or other similar materials. Materials such as kaolin will sinter during the thermal treatment of the construction material and will facilitate the removal of the material from final mold construction. Preferably, the materials are placed in the mold and then compacted. The device used to compact the materials can be flat or have a concave or convex surface to produce a construction material that has a formed surface.

The material is then given its initial heat treatment in an electric oven or in a continuous heating oven, using any oven well • known in the art. A method according to the present invention is that described generally below. As shown in Figure 1, a layer of material 10 of a material is packaged in a mold 12. Preferably, the mold 12 is coated with a fluid layer of kaolin 13 prior to the addition of the layer 10 for help to allow the removal of the finished construction material from the mold 12. The layer 10 has a first surface 14 and a second surface 16. The mold 12 has an internal mold surface 18, a mold bottom 20, an upper part of mold 22 and mold sides 24. The first surface 14 is in contact with the inner mold surface 18 of the mold 12. The layer 10 can then be • optionally compacted and leveled. The layer 10 is then subjected to a first heating step, illustrated by region I of Figure 2.

The layer 10 is then heated so that the first surface 14 reaches a first temperature, which is not greater than the softening temperature, and the second surface 16 reaches a second temperature, which is lower than the first temperature, setting the this mode a temperature gradient across the layer 10. Preferably, this temperature gradient should not be less than about 5%. It has been surprisingly and unexpectedly discovered that this temperature gradient during the first heating step is very essential when the initial material used to produce the layer 10 is glass granulate containing paper and other impurities. It is necessary to have the temperature gradient between the first surface 14 and the second surface 18 of the layer to prevent the appearance of defects on the second surface 18 of the finished construction material. It is important to heat the mold 12 during the first heating step from the bottom of the mold 20 to reach the necessary temperature gradient between the first surface 14 and the second surface 16. When the temperature reaches a temperature higher than 400 ° C, the contaminants In the material used, such as paper and other waste, it will burn, producing combustion gases. By establishing a temperature gradient, the air bubbles between the particles, as well as the combustion gases, move from the first surface 14 and upwards through the layer 10 to the second surface 16 and out of the layer 10. When the temperature of the first surface 14 reaches the softening temperature of the glass granulate, about 720-730 ° C for glass of bottles and windows, the softening of the materials used will start from the adjacent material towards the bottom of the mold 20, and the 5 bubbles of air and gas will move towards the second surface 16 and will exit through this surface. The temperature of the second surface 16 should preferably be at least 50 ° C lower than the temperature of the first surface 14 to prevent the second surface • 10 16 collect pores or bubbles and prevent gases from leaving layer 10. The first and second temperatures will be maintained for a period of time, as shown in region II of Figure 2. All gas bubbles within layer 10 will be eliminated during this stage of heat treatment. This period of time will depend on the thickness of layer 10, as well as the amounts of paper and • residues in the materials used to produce layer 10. For layers of approximately 15 mm, the heating time period will be approximately 15-30 minutes.

After the first heating step, the temperature will rise and a second heating step will be conducted. The layer 10 is further heated to a temperature sufficient to sinter the layer 10. The temperature of the layer 10 is such that a temperature gradient is established through the layer 10 with the first surface 14 having a third temperature and the second surface 16 having a fourth temperature greater than the third temperature. This temperature gradient is shown as region III of Figure 2. This temperature gradient is reversed from the temperature gradient established at the beginning. The third and fourth temperatures are maintained so as to maintain a temperature gradient between the first surface 14 and the second surface 16, as illustrated by region IV of Figure 2. The third temperature, preferably, will be approximately 50-200 ° C, the softening temperature of the glass granulate used to make the layer 10. The fourth temperature will be approximately 200-400 ° C higher than the softening temperature of the material used to make the layer 10. The second surface 16 will reach a maximum temperature during this time. For regular glass containing residual impurities and colorants, this maximum temperature will preferably fluctuate from 950-1100 ° C. The heating during this second stage will preferably be directed in a greater degree towards the upper part of the mold 22 or the sides of the mold 24 than towards the bottom of the mold 20. The time in which the temperature is maintained in this stage will depend on the thickness of the the layer 10 but must be sufficient to sinter the layer 10 to form a construction material having the second surface 16 being substantially free of defects. In a preferred embodiment, a 15 mm layer will be used which will require the third and fourth temperatures to be maintained for approximately 5-15 minutes. The layer 10 is then cooled to a fifth temperature, so that the temperature gradient inside the layer 10 is eliminated, as shown by the region V of Figure 2. The layer 10 is cooled to a nearby temperature, but not greater than, the higher annealing temperature of the glass granulate used to produce the layer 10. This fifth temperature is then maintained for a period of time to reduce the temperature gradient as much as possible, and preferably to 10. -15 ° C for a layer with a thickness of 15 mm, as shown in region VI of Figure 2. The layer 10 is then further cooled. Preferably, this additional cooling is carried out slowly, at a speed of 0.5-5.0 ° C / minute until a temperature of about 10-20 ° C is reached lower than the lower annealing temperature for the glass granulate used to create the layer 10, as illustrated by region VII of Figure 2. Layer 10 is then cooled to room temperature, preferably at a rate of 10-50 ° C / minute, as shown by region VIII of Figure 2. Figure 3 illustrates a two-layer construction material. As shown in Figure 3, a two-layer building material is formed by placing a first layer 26 in the mold 12 having a first surface of a first layer 28 and a second surface of a first layer 30. The first surface of the first layer 28 is in contact with the inner mold surface 18 of the mold 12. Directly on the second surface of the first layer 30 is placed a second layer 32. The second layer 32 has a first surface of a second layer 34 and a second surface of a second layer 36. The second layer 32 is placed on the first layer 26 so that the first surface of the second layer 34 is directly on the second surface of the first layer 30. The first and second layers 26 and 32 are optionally leveled and / or compacted either individually or simultaneously. The first and second layers 26 and 32 are then thermally treated in the manner described above, with the exposed temperatures set on the first surface of the first layer 28 and the second surface of the second layer 36 instead of the first surface 14 and the second surface 16, respectively. If you want a construction material of three • layers, an optional third layer 37 is added to the 5 two layer design, as shown in Figure 5. Generally, in the case of a three layer building material, the first and third layers will comprise approximately 10 layers together. -30% of the total thickness of the layers. The third layer 37 will have a first surface of a third layer 38 and a • second surface of a third layer 39. The third layer 37 is placed directly on the second layer 32 so that the first surface of the third layer 38 is directly on the second surface of the second layer 36. The layers 26, 32 and 37 are optionally compacted and / or leveled already either individually or simultaneously. The layers 26, 32 and 37 are then thermally treated in the above manner • described, with the temperatures set on the first surface of the first layer 28 and the second surface of the first layer 39 instead of the first surface 14 and the second surface 16, respectively. If a multi-layer construction material, consisting of four or more layers, is desired, each layer is placed in a heat-resistant mold in the manner indicated for the two-layer building material, and the first surface of the initial layer and the second surface of the final layer used to calculate the temperatures during the heat treatment. As described above, if there are different multiple key temperatures, ie, softening temperatures, higher annealing temperatures, and / or lower annealing temperatures, for more than one layer in multi-layer construction materials, the most low of each of the key temperatures in the thermal process, such as the point at which the temperature will be maintained during the process. The invention is better described in the following non-limiting examples.

Example 1 Method for Producing a Pink Layer Construction Material With reference to Figures 1 and 5, a fluid suspension of kaolin 13 was applied to the inside of the heat resistant ceramic mold 12 as shown in Figure 1. The layer 10 of the material comprising approximately 18% by weight of sand, approximately 80% by weight of glass granulate, and approximately 2% by weight of colorant was placed in the mold 12. The sand was silicate sand having a particle size less than 1 mm. The glass granulation was produced by grinding transparent waste glass from which the paper and contaminants had not been removed. The size of the glass granulate and the pieces of paper was less than 2 mm. The pigment (Special Inorganic Pigment BK 051-rose, Hydrometalurgicke Zavody Bruntal, Czech Republic) as a fine powder was mixed with the glass granulate and then this mixture was mixed with the sand and placed in the mold 12 as the layer 10. The layer 10 was leveled in the mold 12 without pressure. The mold 12 and the layer 10 were placed in an electric laboratory oven 42, as shown in Figure 5. The oven 42 had lower heating elements 44 and upper heating elements 46. Higher heating 46 were connected in two independent groups, which were controlled independently. A heat exchanger 48 was present within the oven 42 to cool the layer 10. The layer 10 was then subjected to the following heating regime. For the initial heating regime, the lower heating elements 44 heated the mold 12 with the layer 10 to bring the first surface 14 of the ambient temperature to a temperature of 700 ° C for a period of 60 minutes. Initially, only the lower heating elements 44 were used. At twenty minutes in the initial 60 minute heating regime, the upper heating elements 46 were activated and • used to heat the second surface 16 to a temperature of 550 ° C for a period of 40 minutes. After reaching those temperatures, the lower heating elements 44 were maintained at a temperature of 700 ° C and the upper heating elements 46 were kept at the temperature of 550 ° C for 15 minutes. • 10 The second heating regime was then initiated. The upper heating elements 46 were then used to heat the second surface 16 from 550 ° C to 1030 ° C for a period of 30 minutes. At the same time, the heating elements lower 44 were used to heat the first surface 14 from 700 ° C to 850 ° C. Those temperatures are • They kept for 10 minutes. During this time, the layer 10 was sintered together to form a construction material. The layer 10 was then rapidly cooled via cooling air 50 to reduce the temperature of the first surface 14 and the second surface 16 to 530 ° C for a period of 20 minutes. This temperature was maintained for 15 minutes to remove the temperature gradient through the layer 10. The layer 10 was then further cooled to 470 ° C at a rate of 1.0 ° C / minute for a period of 60 minutes. This was followed by additional cooling and annealing by lowering the temperature of layer 10 at 40 ° C for a period of 20 minutes. The product of the final construction material had a thickness of 18 mm with a light pink surface. The construction material had a second defect-free surface 16, which was removed from the mold 12 and cut.

EXAMPLE 2 METHOD FOR PRODUCING A ONE-LAYER BLACK CONSTRUCTION MATERIAL Layer 10 of the material was placed in the heat resistant mold 12 in the manner described in Example 1. Layer 10 comprised approximately 95% residual glass granulate had a particle size of less than 2 mm together with a black dye (Special Inorganic Pigment BK 301 - black, Hydrometalurgicke Zavody Bruntal, Czech Republic). The dye was added as a fine powder in an amount of about 5% by weight and mixed with the glass granulate before being placed in the mold 12.

The layer 10 was then thermally treated in the manner described in Example 1 and a construction material having a final thickness of 18 mm was produced. The construction material had a second smooth surface, free of defects, of black color, with a bluish tint.

EXAMPLE 3 METHOD FOR PRODUCING A MULTI COLOR TWO LAYER CONSTRUCTION MATERIAL With reference to Figures 3 and 6, a fluid suspension of kaolin 13 was applied to the interior of the heat resistant ceramic mold 12 as shown in Figure 3. The first layer 26 of the material comprising approximately 5% by weight of Kaolin powder and approximately 95% by weight of glass granulate was placed in the mold 12. The glass granulate was kept by grinding colored residual glass from which the contaminants of paper had not been removed. The size of the glass granulate and the pieces of paper was less than 12 mm. The thickness of the first layer 26 was 18 mm. The first layer 26 was leveled without compaction. The second layer 36 of the material comprising approximately 95.2% (by weight) of glass granulate and 4.8% (by weight) of various colorants was deposited on the first layer 26 in the manner described above. The glass granulation was produced by grinding transparent waste glass from which the paper contaminants had not been removed. The size of the glass granulate with the pieces of paper was less than 1 mm. To obtain colored beads of different colors and different sizes, various dyes were added to individual portions of the glass granulate in various amounts. To obtain white granules with a size less than 2 mm, the glass granulate was mixed with 7% by weight of Zircon G (Cookson Mathey Corp., USA). To this mixture, about 5% by weight (of the total weight of the glass powder and pigment) of organic binder, sodium carboxymethylcellulose, was added, and then again about 25% by weight (of the total weight of the powder and pigment) of water and mixed until a homogeneous mixture was obtained. This material was then extruded, dried and ground to produce white glass granules with a size of less than 2 mm. The same method was used to obtain the following colored granules. The difference was only in the type of pigment and its quantity. The amount of organic binder and water was the same. Pale blue granules with a size of 1 to 2 mm were obtained by adding 1.2% by weight of Special Inorganic Pigment BK 200 ("Hydrometalurgicke zavody Bruntal", Czech Republic); the size of the granules was 1 to 2 mm. The Dark Blue glass granules were obtained by adding 1.5% by weight of the same pigment BK 200; the size • of the granules was 2 to 4 mm. The black granules were obtained by adding 2% by weight of Pigment of Ceramic F-3790 (Ferro Corporation, Italy); the size of the granules was 1 to 4 mm. The individual portions of the colored granules were mixed in various amounts as follows: White - 60% by weight, Pale Blue - 16%, Dark Blue - 22%, and Black - 2% and were arranged in a design, which mimicked the appearance of natural blue granite to form the second layer 32, which is leveled then without compaction. The second layer 32 had a thickness of 5 mm. 15 The mold 12, the first layer 26 and the second layer 32 were placed in a gas roller furnace 52, as • illustrated in Figure 6. The mold 12 and layers 26 and 32 were moved by the gas rollers 52 through the different temperature zones established therein. Mold 12 and layers 26 and 32 were initially moved to a first zone 56 of the gas roller oven 52. The first zone 56 contained lower burners 58. The lower burners 58 heated the mold 12 and layers 26 and 32 to establish a temperature gradient across the layers 26 and 32 to bring the first surface of the first layer 28 from an ambient temperature to a temperature of 700 ° C and the second surface of the second layer to a temperature of • 550 ° C for a period of 30 minutes, and the temperatures were maintained for 15 minutes. The mold 12 and layers 26 and 32 were then moved via rollers 54 to second zone 60. The second zone contains lower burners 58 and upper burners 62. Layers 26 and 32 were heated to reverse the temperature gradient to • through the layers 26 and 32 to bring the first surface of the first layer 28 to a temperature of 890 ° C and the second surface of the second layer to a temperature of 1050 ° C for a period of 20 minutes, and the temperatures were maintained for 12 minutes. During this time, the layers 26 and 32 were sintered together to form a construction material. • The mold 12 and the layers 26 and 32 were then moved via the rollers 54 to a third zone 64 in the roller furnace 52 where the layers 26 and 32 were cooled quickly via gas oven fans 66 to reduce the temperature of the first surface of the first layer 28 and the second surface of the second layer 36 to 530 ° C for a period of 18 minutes. This temperature was maintained for 15 minutes to remove the temperature gradient across layers 26 and 32. The mold 12 and layers 26 and 32 were then moved via rollers 54 to a fourth zone 68 in the gas roller oven 52, where the layers 26 and 32 were cooled via the gas fan 66 to reduce the temperature of the first surface of the first layer 28 and the second surface of the second layer 36 to 470 ° C for a period of 40 minutes. This temperature was maintained for 5 minutes until final annealing. The mold 12 and the layers 26 and 32 were then moved via the rollers 54 to a fifth zone 70 in the gas roller furnace 52 which contained only gas oven fans 66 and non-burners, where the layers 26 and 32 were cooled via the fans of the gas oven 66 to reduce the temperature of the layers 26 and 32 to room temperature during the 30 minute period. The final building material product has a thickness of 15 mm and a second surface of the second defect-free layer 36. The construction material was removed in the mold 12 and cut out. The brightness of the second surface of the second layer 36 could be adjusted by altering the maximum temperature of the heat treatment.

Example 4 Method for Producing a Multilayer Three Layer Construction Material • With reference to Figures 4 and 6, the first layer 5 26, and the second layer 32, and the third layer 37 of the material were placed in the resistant mold to heat 12 in the manner described in Example 1. First layer 26 is comprised of approximately 40% by weight of slag granulate having a particle size of between 2-3 mm, and about 60% by weight of sand, the sand had a particle size of between 1-2 mm. The thickness of the first layer was 4 mm. The second layer 32 comprised approximately 10% by weight of sand, approximately 10% by weight of slag granulate, and approximately 80% by weight glass granulate. The glass granulate was produced by grinding colored residual glass from which the • Paper contaminants have not been removed. The size of the glass granulate and the pieces of paper was less than 2.5 mm. The size of the slag and sand granules was less than 1 mm. The thickness of the second layer 26 was 18 mm. The third layer 37 was placed on the second layer 32 in the manner described above. The third layer 37 comprised approximately 94% by weight of glass granulate and 6% by weight of colorant. The glass granulation was produced by grinding transparent waste glass from which the paper contaminants had not been removed. The final size of the glass granulate containing paper waste was less than 1 mm. To obtain colored granules in different colors and different sizes, various colorants were added to individual portions of the glass granulate in various amounts. The procedures for producing colored granules were as in Example 3, except that instead of a binder, an inorganic binder, Na2Si03, was used. Black and white glass granules were created which had the same color as those of Example 3 using the amounts of pigment used in Example 3. The amount of binder was 5% by weight of the glass granulate and pigment. The individual portions of colored granules were mixed in various amounts as follows: White - 85% by weight and Black - 15% by weight, and arranged in a design which mimicked the appearance of natural granite to form the third layer 37, the which was then leveled without compaction. The third layer 37 had a thickness of 5 mm. Layers 26 and 32 and 37 were then thermally treated in the manner described in Example 3, with the temperatures measured on first surface of the first layer 28 and the second surface of the third layer 39 instead of the first surface of the first layer. layer 28 and second surface of second layer 36, respectively. In the heat treatment, the heating times were changed from room temperature to a temperature of 700 ° C for a period of 45 minutes, and the temperature was maintained for 20 minutes due to the greater thickness of the materials over those of Example 3. heating was also carried out at a maximum temperature of 1050 ° C for a period of 30 minutes, and the temperature was maintained for 20 minutes. The cooling portion of the process was changed as follows: rapid heating to 530 ° was for a period of 27 minutes and this temperature was maintained for 25 minutes. The cooling from 530 ° to 470 ° C was for a period of 75 minutes. A construction material was produced that had a final thickness of 27 mm. The construction material had a third smooth surface, free of defect. It should be understood that the invention is not limited to the particular embodiments described herein, as illustrative, but encompasses all those modified forms thereof, which fall within the scope of the following claims.

Claims (48)

1. CHAPTER CLAIMEDICATORÍO ^ Having described the invention, it is considered as a novelty and, therefore, what is contained in the following is claimed CLAIMS: 1. A method for producing a construction material, characterized in that it comprises the steps of: (a) placing a layer in a mold, the layer having a first surface and a second surface, the layer comprising a glass granulate; (b) heat the layer, so that a temperature gradient is established across the layer, with the first 15 having a first temperature no greater than the softening temperature, and the second surface having a second temperature lower than the first temperature; (c) maintaining the first and second temperatures 20 for a selected period of time; (d) heating the layer to a temperature sufficient to sinter the layer, to produce a temperature gradient across the layer, with the first surface, having a temperature, and the second surface having 25 a fourth temperature greater than the third temperature; (e) maintaining the third and fourth temperatures for sintering the layer in a construction material having a second surface substantially free of defects; and (f) cooling and annealing the construction material.
2. 2. The method of compliance with the claim 1, characterized in that the layer comprises slag granules, the layer is free of sand.
3. 3. The method of compliance with claim 1, characterized in that the layer is free of slag granulate and sand.
4. 4. The method according to claim 1, characterized in that the layer further comprises a binder.
5. 5. The method according to claim 2, characterized in that the layer further comprises a binder.
6. 6. The method according to claim 3, characterized in that the layer additionally comprises a binder.
7. 7. The method of compliance with the claim 1, characterized in that the layer additionally comprises a colorant.
8. 8. The method of compliance with the claim 2, characterized in that the layer additionally comprises a colorant.
9. 9. The method according to claim 3, characterized in that the layer additionally comprises a colorant. The method according to claim 5 3, characterized in that the glass granulate has a size in the range of 0.5-5 mm. The method according to claim 1, characterized in that step (f) further comprises: • 10 (i) cooling the layer to a fifth temperature, which is equal to or less than the upper annealing temperature; (ii) maintain the fifth temperature for a sufficient period to allow the first surface and 15 the second surface reach approximately the same temperature and the temperature gradient is dissipated through the layer; • (iii) cooling the layer to a sixth temperature at a rate of about 0.5-5.0 ° C / minute until a temperature is reached about 10-20 ° C lower than the lower annealing temperature; and (iv) cooling the layer to room temperature at a rate of about 5-50 ° C / minute. The method according to claim 25 2, characterized in that step (f) further comprises: (i) cooling the layer to a fifth temperature, which is equal to or less than the upper annealing temperature; (ii) maintain the fifth temperature during a • sufficient period to allow the first surface and 5 the second surface reach approximately the same temperature and the temperature gradient is dissipated through the layer; (iii) cooling the layer to a sixth temperature at a rate of approximately 0.5-5.0 ° C / minute until • a temperature of about 10-20 ° C lower than the lower annealing temperature is reached; and (iv) cooling the layer to room temperature at a rate of about 5-50 ° C / minute. The method according to claim 15 3, characterized in that step (f) further comprises: (i) cooling the layer to a fifth temperature, which is equal to or less than the upper annealing temperature; (ii) maintain the fifth temperature during a Sufficient period to allow the first surface and the second surface to reach approximately the same temperature and the temperature gradient to be dissipated through the layer; (iii) cooling the layer to a sixth temperature at a rate of about 0.5-5.0 ° C / minute until a temperature about 10-20 ° C lower than the lower annealing temperature is reached; and (iv) cooling the layer to room temperature at a rate of about 5-50 ° C / minute. 14. A construction material, characterized in that it is made in accordance with the process of claim 1. 15. A construction material, characterized in that it is made in accordance with the process of claim 2. 16. A construction material, characterized because it is made in accordance with the process of claim 3. 17. A method for producing a construction material, characterized in that it comprises the steps of: (a) placing a first layer in a mold, the first layer having a first surface and a second surface, the first layer comprises glass granulate; (b) depositing a second layer on the first layer, the second layer has a first surface and a second surface, so that the first surface of the second layer is directly placed on the second surface of the first layer, the second layer comprises granulated glass; (c) heating the first and second layers so that a temperature gradient is established across the layers, with the first surface of the first layer having a first "temperature no greater than the softening temperature, and the second surface of the second layer having a second temperature lower than the first temperature of the first layer; (d) maintaining the first and second temperatures; (e) heating the first and second layers at a temperature sufficient to sinter the first and second layers to produce a temperature gradient through the first and second layers, with the first surface of the first layer having a third temperature, and the second surface of the second layer having a fourth temperature greater than the third temperature; (f) maintaining the third and fourth temperatures for sintering the first and second layers in a building material having a second surface substantially free of defects of the s second layer; and (g) cooling and annealing the construction material. The method according to claim 17, characterized in that at least one of the first and second layers comprises the slag granulate, each layer being free of sand. 19. The method according to claim 17, characterized in that each of the first and second layers are free of granules of "Slag and sand." 5 20. The method according to the claim 17, characterized in that at least one layer additionally comprises a binder. 21. The method according to the claim 18, characterized in that at least one layer comprises, in addition, a binder. 22. The method of compliance with the claim 19, characterized in that at least one layer additionally comprises a binder. 23. The method according to claim 15, characterized in that the first layer has a thickness of about 5-30 mm, and the second layer has a thickness of about 1-6 mm. • The method according to claim 17, characterized in that step (g) further comprises: (i) cooling the first and second layers to a fifth temperature, which is equal to or less than the higher annealing temperature; (ii) maintain the fifth temperature for a sufficient period to allow the fifth surface of 25 the first layer and the second surface of the second layer reach approximately the same temperature and the temperature gradient dissipates through the layers; (iii) cooling the first and second layers to a sixth temperature at a rate of about 0.5-5.0 ° C / minute, until a temperature is reached about 10-20 ° C lower than the lower annealing temperature for both of the first and second layers; and (iv) cooling the first and second layers at room temperature at a rate of about 5-50 ° C / minute. 25. The method according to claim 18, characterized in that step (g) further comprises: (i) cooling the first and second layers to a fifth temperature, which is equal to or less than the upper annealing temperature; (ii) maintaining the fifth temperature for a period sufficient to allow the fifth surface of the first layer and the second surface of the second layer to reach approximately the same temperature and to dissipate the temperature gradient across the layers; (iii) cooling the first and second layers to a sixth temperature at a rate of about 0.5-5.0 ° C / minute until a temperature is reached about 10-20 ° C lower than the lower annealing temperature for both of the first and second second layers; and (iv) cooling the first and second layers at room temperature at a rate of about 5-50 ° C / minute. 26. The method according to claim 5 19, characterized in that step (g) further comprises: (i) cooling the first and second layers to a fifth temperature, which is equal to or less than the upper annealing temperature; (ii) maintain the fifth temperature during a A period sufficient to allow the first surface of the first layer and the second surface of the second layer to reach approximately the same temperature and the temperature gradient to be dissipated through the layers; (iii) cool the first and second layers to a 15 sixth temperature- at one: speed of approximately 0.5- 5.0 ° C / minute until a temperature is reached approximately 10-20 ° C lower than the temperature of • lower annealing for both of the first and second layers; and (iv) cooling the first and second layers at room temperature at a rate of about 5-50 ° C / minute. 27. The method according to claim 17, characterized in that the temperature gradient between the first and second layers in step (c) is approximately 25 5% or more. 28. The method in accordance with the claim 18, characterized in that the temperature gradient between the first and second layers in step (c) is about 5% or greater. 29. The method of compliance with the claim 19, characterized in that the temperature gradient between the first and second layers in step (c) is about 5% or greater. 30. A construction material, characterized in that it is made in accordance with the process of claim 17. 31. A construction material, characterized in that it is made in accordance with the process of claim 18. 32. A construction material, characterized because it is done in accordance with the process of claim 19. 33. A method for producing a construction material, characterized in that it comprises the steps of: (a) placing a first layer in a mold, the first layer having a first surface and a second surface, the first layer comprises glass granulate; (b) depositing a second layer on the first layer, the second layer has a first surface and a second surface, so that the first surface of the second layer is directly placed on the second surface of the first layer, the second layer comprises granulated glass; • (c) deposit a third layer on the second 5 layer, the third layer has a first surface and a second surface, so that the first surface of the third layer is placed directly on the second surface of the second layer, the third layer comprises the glass granulate; 10 (d) heating the layers so that a temperature gradient is established across the layers, with the first surface of the first layer having a first temperature no greater than the softening temperature, and the second surface of the third layer having a second 15 temperature lower than the first temperature; (e) maintaining the first and second temperatures; (g) heating the layers to a temperature • sufficient to sinter the layers to produce a temperature gradient across the layers, with the first surface of the first layer having a third temperature, and the second surface of the third layer having a fourth temperature greater than the third temperature; (g) maintaining the third and fourth temperatures to sinter the layers in a construction material having a second surface substantially free of defects of the third layer; and (h) cooling and annealing the construction material. 34. The method according to claim 33, characterized in that at least one layer comprises the slag granulate, each layer is free of sand. 35. The method according to claim 33, characterized in that each layer is free of slag granules and sand. 36. The method of compliance with the claim 33, characterized in that at least one layer additionally comprises a binder. 37. The method according to the claim 34, characterized in that at least one layer additionally comprises a binder. 38. The method of compliance with the claim 35, characterized in that at least one layer additionally comprises a binder. 39. The method according to claim 35, characterized in that the first layer has a thickness of approximately 5-30 mm, and the second layer has a thickness of approximately 1-6 mm. 40. The method according to claim 33, characterized in that step (h) further comprises: (i) cooling all the layers to a fifth temperature, which is equal to or less than the upper annealing temperature; • (ii) maintain the fifth temperature during a 5 sufficient period to allow the first surface of the first layer and the second surface of the third layer to reach approximately the same temperature and to dissipate the temperature gradient across all the layers; (iii) cool all layers to a sixth 10 temperature at a rate of about 0.5-5.0 ° C / minute until a temperature is reached about 10-20 ° C lower than the lower annealing temperature for all second layers; and (iv) cooling all layers at room temperature at a rate of about 5-50 ° C / minute. 41. The method according to claim 34, characterized in that step (h) further comprises: # (i) cooling all layers to a fifth temperature, which is equal to or less than the upper annealing temperature; (ii) maintaining the fifth temperature for a period sufficient to allow the first surface of the first layer and the second surface of the third layer to reach approximately the same temperature and dissipate the 25 temperature gradient across all the layers; (iii) cooling all layers to a sixth temperature at a rate of about 0.5-5.0 ° C / minute until a temperature is reached about 10-20 ° C lower than the lower annealing temperature for all second layers; and (iv) cooling all layers at room temperature at a rate of about 5-50 ° C / minute. 42. The method according to claim 35, characterized in that step (h) further comprises: (i) cooling all layers to a fifth temperature, which is equal to or less than the upper annealing temperature; (ii) maintaining the fifth temperature for a period sufficient to allow the first surface of the first layer and the second surface of the third layer to reach approximately the same temperature and to dissipate the temperature gradient across all the layers; (iii) cooling all layers to a sixth temperature at a rate of about 0.5-5.0 ° C / minute until a temperature about 10-20 ° C is reached lower than the lower annealing temperature for all layers; and (iv) cooling all layers at room temperature at a rate of about 5-50 ° C / minute. 43. The method in accordance with the claim 33, characterized in that the temperature gradient between the first and third layers in step (d) is about 5% or greater. 5 44. The method according to the claim 34, characterized in that the temperature gradient between the first and third layers in step (d) is about 5% or greater. 45. The method according to the claim • 10 35, characterized in that the temperature gradient between the first and third layers in step (d) is about 5% or greater. 46. A construction material, characterized in that it is made in accordance with the process of 15 claim 33. 47. A construction material, characterized in that it is made in accordance with the process of • claim 34. 48. A construction material, characterized in that it is made in accordance with the process of claim 35.