RU2190522C1 - Method and form for manufacture of interior-lining gypsum products - Google Patents

Abstract

FIELD: manufacture of gypsum decorative products. SUBSTANCE: method consists in preparation of a gypsum mix (1 part of water and 2.2-2.5 parts gypsum), placement of the mix in a form at a vibration frequency of the vibrating table of 250-500 vibrations per minute, uniform vibrating tamping during 15-35 s, disengagement of the vibrating table, pressing-in of the product by the pressing plane, curing of the product up to the complete hardening, dismantling of the forms, drying at a natural plenum-exhaust ventilation during 5-6 h and treatment of the product by a water-repellent compound with a subsequent panting. The form ash a mould made with fields projecting from the form boards around the edges. Each inner side of the form board is chamfered with formation of a gap between the mould and the form boards, 0.5-1 mm wide, and the upper inner edge of the board is chamfered at an angle of 10-15 deg. For casting of the mould use is made of an adhesive solution and a dry mix of gypsum and cement. EFFECT: enhanced quality of gypsum products with a relief pattern. 6 cl, 2 dwg

Description

 The invention relates to a technology for manufacturing interior-facing products from gypsum and can be used for the production of building materials, including for copying ceramic relief tiles in gypsum.

 A known method of manufacturing building products with embossed patterns according to copyright certificate 1409457, class. 28 B 11/00 of 07/15/88, including installation of a matrix with grooves and channels and supplying it with an elastic rubber gasket, laying a polymer film on a matrix, laying and vibration-sealing of a concrete mixture, heat and moisture treatment and formwork removal.

 The disadvantage of this method is the complex process of manufacturing building products, implemented by the complicated design of the matrix with rubber gaskets and additional equipment that can be used only in the factory.

 The closest technical solution to the claimed is a method of manufacturing an interior-facing gypsum products, a mold for the manufacture of interior-facing products according to the patent of the Russian Federation 2087308, cl. In 28 In 11/00, 7/34 from 08/20/97, in which the method includes preparing the molding mixture, pouring it into the mold in an excess volume, laying the spacer matrix in the mold beforehand, shaking the mold with the sealed cover closed, holding to complete hardening, stripping the product with a gasket, its separation, drying, finishing and processing of the product with a water-repellent composition.

 The mold that implements this method includes a pallet, longitudinal and transverse sides, a removable matrix with a relief pattern on the pallet, a polymer gasket congruent to the working surface of the mold and equipped with shoulders located on the sides of the mold and covering them outside the height of the mold, is used as the matrix has a removable sealing cover, made with the possibility of support on its shoulders.

 A disadvantage of the known analogue is the complex design of the matrix with shoulders, which completely cover the sides of the mold from the outside to the very base, which complicates the formwork removal and removal of the matrix with the product without damage.

 In addition, the technological capabilities of the mold are limited in that the mold can only work when pouring a liquid solution, which does not give sufficient strength to the products and entails a large consumption of building material. In the case of pouring a thick solution by pressing, strong pressure is exerted on the sides of the pallet form and the matrix in the mold is jammed together with the products.

 The technical task of the invention is the creation of a simplified and inexpensive method for the manufacture of facing gypsum products with increased density and strength, as well as the expansion of the technological capabilities of the mold, producing in this way a different assortment of gypsum products of high quality.

To solve the technical problem in the proposed invention, including the method of preparing a gypsum mixture, laying it in a mold with a pre-laid matrix with a relief pattern, holding to hardening, stripping the product with the matrix, its separation from the product and drying of the product (features similar to the analogue) , new features have been introduced, consisting in the fact that the gypsum mixture is prepared at the rate of 1 part water and 2.2-2.5 parts of gypsum, the mixture is mixed until a mixture of uniform consistency is obtained, the mixture is laid in a tray the totals vibrations of the vibrating table 250-500 vibrations per minute, uniformly vibrocompress the mixture on the working surface of the matrix for 15-35 s, after which the vibrating table is turned off, the mold with the product is mounted on the table and pressed with a pressing plane until the contour of the inner perimeter of the bead appears, the product is held in until hardening is complete, the pressing plane is removed and, first, the die along with the die is removed from the mold, and then the die is removed from the die with the gates removed, after which the articles are dried under natural exhaust ventilation for 5-6 hours, after which the product is treated with a water-repellent composition, followed by color painting of the tiles. As a water-repellent composition, an Aquasil alkaline solution or any hydrophobic coating is used. In the form, including a pallet made in one piece with the sides, a removable matrix with a relief pattern, a pressing surface (features similar to the analogue), new features have been introduced, consisting in the fact that the matrix is made along its entire perimeter with fields protruding beyond the sides of the form , on each inner side of the sides of the form, the chamfer is removed and a gap is formed between the matrix and the sides of the mold with a width of 0.5-1 mm, along the upper inner edge of the side, stepping back 1-2 mm, the chamfer is taken at an angle of 10-15 ^o . For casting the mold, use a water-glue solution and a dry mixture of gypsum and cement. As a water-glue solution, water and PVA glue are taken in 10-15% of the total amount of water, and cement is taken 10-20% of the total amount of dry mix. As a matrix, a plastic ceiling coating can be used. As a pressing plane, any plane having release properties with a relief pattern can be used.

 Analyzing the set of essential features of the claimed invention, it is seen that in the above analogues there are no signs inherent in the claimed invention, and therefore, the method of manufacturing interior-facing gypsum products and the mold for their manufacture meets the criterion of "novelty."

 From the prior art in the field of construction and production of building materials and structures (according to patent research), technical solutions with a combination of features inherent in the claimed invention have not been identified, in connection with which the method of manufacturing interior-facing gypsum products and the form for their manufacture meets the criterion of "inventive level".

 The results of the experiments at home confirm the feasibility of the claimed invention by the features characterizing it and the production of high quality interior-facing products with a high degree of density and strength, and therefore the claimed invention meets the criterion of "industrial applicability".

 The presence of the criteria of novelty, inventive step and industrial applicability ensures the patentability of the method of manufacturing interior-facing gypsum products and forms for their manufacture.

 The essence of the invention is illustrated by drawings, where figure 1 shows a form in General, in a perspective view; figure 2 is the same, a cross section in figure 1.

 The form contains a pallet 1, made in one piece with the sides 2 and having a relief pattern 3, a removable matrix 4 with a relief pattern and wide fields 5, protruding beyond the sides of the form around the entire perimeter of the matrix. According to the internal height of the sides 2, a gap 6 with a width of 0.5-1 mm is made between them and the matrix. On top of the field 5, the matrix 4 is pressed in the upper plane of the side 2 by the pressing plane 7. Inside the mold, an insert 8 is installed, around the sides 2 there is a formwork 9.

 The pressing plane 7 can be made in the form of plywood with a self-adhesive embossed embossed film glued to it or plexiglass with an embossed pattern applied by hot pressing or thermal evacuation, and also in the form of embossed glass reinforced with a self-adhesive polyethylene film.

 The form of the pallet is made as follows. An even plane, such as glass, is placed on the vibrating table, an insert 8 is installed on top to protect the matrix from deflection during pouring of the gypsum mortar, a removable inverted matrix 4 with a relief pattern is installed on the insert 8, which is fixed with adhesive tape to a flat plane, for example, to glass. Then, on the wide fields of the matrix 5, formwork 9 is installed and it is connected with glass with tape.

 For casting the mold-pallet 1 prepare a solution containing PVA glue 10-15% of the total amount of water to give increased strength to the form and increase its service life. Cement in 10-20% of the total amount of dry mixture is added to dry gypsum.

 The ratio of water and dry components, taken equal to 1: 2.2-2.5 hours, respectively, provide obtaining a molding thick consistency at the yield strength.

The vibrating table is turned on, the molding mixture is laid out in the center of the inverted matrix 4, the mixture is vibro-compacted over the entire container for 15-35 s. With a vibration frequency of 250-500 vibrations per minute, air bubbles are removed from the mixture, after which the pressing plane 7 is installed on the formwork 9. After complete curing, formwork is performed after 20-35 minutes, the matrix 4 is separated and the workpiece of the mold is finished. In order to avoid jamming of the products in the mold together with the matrix 4 in the resulting pallet form 1, the chamfer is removed from the inner sides 2 by 0.5-1 mm on each side, thus, a gap 6 is formed between the sides 2 of the mold and the matrix 4. Departing from the inner the edges of the bead 2 by 1-2 mm, along the upper edge of the bead 2 a chamfer is removed at an angle of 10-15 ^o to reduce the pressure on the fields of the matrix 4 and protect them from rapid wear. Due to the reduction in the area of contact of the pressing plane 7 with the fields of the matrix 4, the sprues are cut off from the product immediately upon pressing, as a result of which, when stripping the tile product, the fields 5 of the matrix 4 are self-cleaning. The mold is dried under natural conditions, after which the outside of the pan 1 is pasted with tape to prevent adhesion of gypsum crumbs to it.

 A method of manufacturing interior-facing products, such as tiles, is as follows.

A pallet form 1 with a matrix 4 is inserted onto the vibrating table. A solution is prepared at the rate of 1 part water and 2.2-2.5 parts gypsum. The solution is stirred until a mixture of uniform consistency is obtained. A vibrating table is turned on with a vibration frequency of 250-500 vibrations per minute and the gypsum mass is laid out in a pallet form 1 with a matrix 4 embedded in it, where the mixture is evenly distributed over the working surface of the matrix 4 for 15-35 s. Then the vibrating table is turned off, the mold with the molded product is mounted on the table, covered with a pressing plane and pressed into the contour of the inner perimeter of the bead 2. Then the product is kept in the mold until it is completely hardened. When using low-grade gypsum, the hardening time can be reduced by using warm water with a temperature of 25-35 ^o C. when dissolving. After the hardening process is completed, the pressing plane is easily removed, the die with the product is removed from the mold, then the product is removed from the matrix, the gates are removed and placed on drying in rack light boxes, which are suspended to the wall under the exhaust hole.

Natural supply and exhaust ventilation is carried out for 5-6 hours, as a result of which the air flow going from bottom to top passes through the entire tile, takes moisture from it, drains the tile and goes out through the exhaust hole. The product can be dried by various ventilation methods, for example natural, forced or forced and with the supply of hot air, but the drying temperature is allowed no more than 60 ^o C. After drying, the finished product is removed from the boxes and treated with an alkaline water-repellent composition “Aquasil” using pneumatic and electric sprayer. If it is necessary to make the tile colored, then first the background layer is applied with a spray or, alternatively, the primer is made with acrylic or alkyd enamel. Then, using an airbrush, decorative shades are applied to each tile individually at an angle of 0-45 ^o . Then the final layer - the varnish coating is applied by spray.

 For home conditions, acrylic enamels and varnishes, water-soluble initially, are most suitable. Due to polymerization, a very strong and resistant water-repellent layer forms on the tile surface. The absence of harmful fumes allows covering the tiles at home without personal respiratory protection (unlike nitro enamel paints).

 In addition, aniline dyes, gouache and other water-soluble dyes can be used to color the tiles. Combined colors are selected, for example, for painting tiles under "malachite", various shades of green and black are selected, under "granite" - gray and black colors, under "marble", for example, blue and gray, etc.

Thus, the proposed method for the manufacture of interior-facing gypsum products and the form for their manufacture has several advantages compared to analogues:
1. Provides obtaining interior-facing products, such as gypsum tiles, high quality with a high degree of density and strength.

 2. Provides savings of dry material by 15-20%.

 3. The technological capabilities of the form and method for the production of a different assortment of facing tiles have been expanded, including at home, in which the matrix can be made by thermal vacuum from any ceramic tile with a relief pattern, and any ready-made fragment of the ceiling can be used as a matrix embossed plastic upholstery.

Claims (6)

 1. A method of manufacturing interior-facing gypsum products, including the preparation of a gypsum mixture, laying it in a mold with a pre-laid matrix with a relief pattern, stripping the product with a matrix, its separation from the product and drying the product, characterized in that the gypsum mixture is prepared at the rate of 1 part of water and 2.2-2.5 parts of gypsum, mix the mixture to obtain a mixture of uniform consistency and lay the gypsum mixture in a pan with a vibration table vibration frequency of 250-500 vibrations per minute, uniformly vibroplot take the mixture over the working surface of the matrix for 15-35 s, after which the vibrating table is turned off, the mold with the product is mounted on the table and pressed with a pressing plane until the contour of the inner perimeter of the bead appears, the product is held in the mold until it completely hardens, the pressing plane is removed and removed from the mold first, the matrix together with the product, then the product from the matrix with the removal of the sprues, and the products are dried with natural supply and exhaust ventilation for 5-6 hours, after which the product is treated with water vayuschim composition, followed by color painting tiles.  2. The method according to claim 1, characterized in that the alkaline solution or any hydrophobic coating is used as the water-repellent composition. 3. A mold for the manufacture of interior-facing gypsum products, including a pallet made in one piece with the sides, a removable matrix with a relief pattern, a pressing plane, characterized in that the matrix is made around its perimeter with fields protruding beyond the sides of the form, with each inner the side of the sides of the mold is chamfered to form a gap between the die and the sides of the mold with a width of 0.5-1 mm, and along the upper inner edge of the side with an indent of 1-2 mm, the chamfer is taken at an angle of 10-15 ^o , and water-glue was used for casting the mold R mortar and dry mix of gypsum and cement.  4. The mold according to claim 3, characterized in that a water-glue solution of water, 10-15% PVA glue of the total amount of water and a dry mixture of gypsum and 10-20% of cement of the total amount of the dry mix were used for casting the mold.  5. The mold according to claim 3, characterized in that a plastic ceiling coating is used as a matrix.  6. The mold according to claim 3, characterized in that a plane having release properties with a relief pattern is used as a pressing plane.

Images