RU2430830C1 - Method of producing natural stone imitators - Google Patents

Abstract

FIELD: process engineering.

SUBSTANCE: invention relates to construction, namely, to method of fabricating articles imitating natural stones. Proposed method comprises producing convex female die with relief surface, producing layer from glass fiber blanket, applying binder layer from polyester resin with hardener and applying layer of coarse sand and/or pebble gravel. Separation layer with low adhesion to female die material is applied on outer surface of said die. First binder layer from polyester resin with hardener is applied on separation layer whereto pressed is piece-like glass fiber blanket to copy aforesaid relief surface. Second binder layer from polyester resin with hardener is applied on piece-like glass fiber blanket to allow penetration of polyester resin into said blanket. Air bubbles are removed from binder layers by, for example roller to apply second binder layer of coarse sand and pebble gravel on second binder not yet hardened, Sand particle size making 2-6 mm. Now, said binder layers are hardened in heating to produce article carcass to be removed from female die.

EFFECT: higher quality and strength.

4 cl, 5 dwg

Description

The invention relates to methods for producing synthetic structural products, replacing whole natural granites, diabases and other hard stone breeds used as decorative protective and other structures.

Artificial stones are an imitation of boulders protruding above the ground (granite and sandstone blocks) and are designed to decorate landscapes in summer cottages and in urban environments.

Obtained by the proposed method, products with an internal cavity can cover sewer manholes, wells, stumps, protruding concrete and steel structural elements of pumping equipment and other ugly places on the landscape.

Artificial stones are indistinguishable from natural ones.

If plants are planted next to such an artificial stone, natural and beautiful compositions are obtained.

A known method of manufacturing a natural stone imitating artificial building stone [1], including the preparation of concrete mixtures, one of which is painted, loading a vibrated layer of unpainted concrete mixture into a mold, its preliminary pressing, applying a second layer of the painted mixture and the final vibrocompression of the whole product, this colored mixture is prepared in the form of mixtures of several colors corresponding to the components of the simulated material, and after applying the second layer of the colored mixture lead intermittent loading it in conditions of vibration boot box of the third, fourth and other layers of differently colored mixtures.

There is also known a method of manufacturing a two-composite artificial building stone [2], according to which a prefabricated core made of low heat conductive and lightweight material is mounted on a pallet of the mold and centered relative to its sides, after which the mold is filled with concrete mixture to form a shell after hardening.

Known methods [1, 2] are intended to produce artificial stones used in construction and having great material consumption and limited functionality, due to the inability to use them as decorative covering elements, for example, when creating artistic elements used in landscape gardening landscapes.

Closest to the technical nature of the proposed technical solution is a method of manufacturing products that simulate natural stone, implemented in a decorative covering element [3].

According to this method, a matrix is made, on the outer surface of which a layer of glass mat and a layer of polyester resin with a hardener are applied, into which natural chips of various colors (quartz, marble, granite, quartzite, coil, jasper, etc.) are introduced.

However, the known method does not provide products with high quality and durability. Low quality is caused by the use of glass mat with a large area to cover the embossed surface of the matrix form, which does not allow to fully reproduce (copy) small details of the relief surface of the matrix form. In addition, the known method does not provide quick and high-quality separation of the product after it has hardened from the matrix form due to the high adhesion of the polyester resin with the hardener to the material of the matrix form.

The insufficient strength of the product is due to the presence of one binder layer of polyester resin, which does not allow to effectively impregnate glass mat over the entire volume of the material.

The technical result, which consists in eliminating the noted drawbacks, is achieved in the proposed method for the manufacture of products imitating natural stone, including forming a convex matrix with a relief surface, forming a layer of glass mat, applying a binder layer of polyester resin with a hardener, and applying a layer of coarse sand and / or stone chips, in that a separation layer with low adhesion to the material of the matrix form is applied to the outer surface of the matrix form, on top of the separation layer on a first binder layer of polyester resin with a hardener is applied, to which piece piece glass mat is pressed to ensure the relief of the mold surface is copied, a second binder layer of polyester resin with hardener is applied over the piece of piece glass mat to ensure that the polyester resin is embedded in the glass mat, bubbles are removed from the binder layers coarse-grained sand and stone chips with a particle size of 2-6 mm are applied by mechanical action, for example, with a roller, and applied to the uncured second bonding layer which provide the hardening of the bonding layers by heat and get the frame of the product, which is removed from the mold.

In order to further improve the quality and similarity with natural stone, a fraction of colored stone crumb 1-3 mm in size is locally introduced into the uncured layer of coarse sand and stone chips to simulate granite stains and / or veins of mineral rocks.

In this case, the curing of the binder layers is carried out at a temperature of +10 to +25 degrees Celsius for at least 24 hours or at a temperature below +10 degrees Celsius for at least 72 hours.

To further increase the strength and durability, the product is subjected to post-hardening for 3 to 10 days.

To simplify the manufacturing technology, the mold is made of plastic sheet 1-2 mm thick.

To eliminate the possibility of injury when using the product, the embossed surface of the product is polished to remove sharp protruding elements.

To facilitate the removal of the finished product from the mold matrix, a plastic film 40-60 microns thick is used as the separation layer.

The invention is illustrated by drawings and photographs, where:

- figure 1 shows the matrix form without an internal cavity, fashioned from a plastic material (for example, clay);

- figure 2 shows a lightweight form matrix made of plastic with an internal cavity;

- figure 3 illustrates the manufacturing operations of the manufacture of the product according to the proposed method using the matrix form without an internal cavity,

- figure 4 presents a photograph of a product made by the proposed method and raised above the sewer;

- figure 5 presents a photograph of a product imitating a natural stone located with a landscape element - coniferous tree.

The proposed method is as follows.

First, a convex matrix form is created with a relief surface that imitates the shape of a natural stone (for example, a boulder or others).

In its manufacture works a painter-sculptor who creates a beautiful natural shape.

The matrix form is made continuous in the form of a block 1 (Fig. 1) or from fiberglass sheet 2 (Fig. 2) 1-2 mm thick.

On the outer surface of the mold 1 (2), a separation layer 3 is applied (Fig. 3a), intended to facilitate the removal of the finished product at the final stage of its manufacture. Layer 3 has low adhesion to the material of the matrix form 1 (2) and prevents the polyester resin from adhering to the matrix form.

As the separation layer 3, a plastic film 40-60 μm thick is used.

Then, a first bonding layer 4 of polyester resin with a hardener (in the required ratio) is applied in a thin layer to the separation layer — FIG. 3b.

After that, glass mat 5 is placed in pieces on the first binder layer of polyester resin and pressed by a roller or manually so that it fits tightly and copies the relief of the matrix form (Fig. 3c).

The use of piece glass mat 5 provides the most tight fit to the embossed surface and the copying of small embossed elements of the surface of the matrix form 1 (2).

A second binder layer 6 of a polyester resin with a hardener is applied to the glass mat 5 (Fig. 3d). In this case, glass mat 5 is well impregnated with resin. Air bubbles created in the layers of glass mat and resin are removed mechanically by rolling with a roller or brush.

Coarse-grained sand (fraction 1-3 mm) and / or stone chips 7 of size 2-6 mm (FIG. 3e) is applied to the yet not hardened second resin bonding layer 6 of the resin to form an abrasive surface after hardening the resin.

In the hardened layer of coarse sand and stone chips, a fraction of colored stone chips 1-3 mm in size is locally applied to simulate granite spots or veins of mineral rocks.

The resulting product hardens at a temperature of +10 to +25 degrees Celsius for at least 24 hours (at a lower temperature, the curing time is at least 72 hours).

After hardening, the resulting product frame (Fig.3f) is removed from the matrix form 1 (2).

For added strength, the product is post-cured for 3-10 days.

To increase security, the embossed surface of the product is polished to remove sharp protruding elements.

An example implementation of the method.

The matrix form is made whole 1 (from clay, gypsum or natural stone) or hollow 2 (from fiberglass 2-6 mm thick).

For the separation layer 3 is used a polymer film 3 with a relative thickness d _sec. / D = 0.005-0.2, where d is the absolute thickness of the separation layer, and D is the absolute thickness of the skeleton of the product obtained by the proposed method (D = 5-8 mm).

For the bonding layers 4 and 6, polyester resins of all grades can be used, as well as epoxy resins and gelcoats, in particular polyester resins of grades M-105 and M-101 due to their low price. Suitable hardeners are any hardeners recommended for fiberglass, gelcoats and epoxy resins, in particular the Butanox M-50 hardener, which is added to the polyester resin. The first binder layer 4 is applied with a relative thickness d of _{resin 1} / D = 0.06-0.2, where d of _{resin 1} is the absolute thickness of the first binder layer 4.

A layer of glass mat 5 is laid in pieces on the first bonding layer 4, which is pressed so that it fits tightly and copies the relief of the matrix form 1 (2).

The glass _mat layer 5 has a relative thickness d _cm. / D = 0.04-0.1, where d _cm. - the absolute thickness of the glass mat.

Glass mat 5 provides a reinforcing effect and gives the product strength.

Emulsion glass mat M501 with a density of 300 g / m2 is used. For products of large sizes can be used glass mat with a density of 450 to 900 g / m2, as well as glass cloth.

A second binder layer 6 of a polyester resin with a hardener is applied to the glass mat 5. In this case, glass mat 5 is impregnated with resin, and air bubbles formed in the layers of glass mat 5 and resin 4 and 6 are removed mechanically with a roller or brush.

The second binder layer 6 is applied with a relative thickness d of _resin2 / D = 0.1-0.3, where d of _resin2 is the absolute thickness of the second binder layer 6.

A layer 7 of coarse sand and stone chips with a particle size of 2-6 mm, which, after hardening the resin, forms the abrasive surface of the carcass, is applied to the resin that has not yet cured.

The operations of the proposed method can be performed manually or using small-scale mechanization. The resin is applied with a brush, the facing layer - with hands in PVC gloves, polishing is carried out with sharp metal tools, the abrasive layer is sprayed with a special dosing unit.

Thus, the outer surface of the product is formed by glued natural elements of various colors (crumbs of quartz, marble, granite, quartzite, coil, jasper, etc.).

After hardening, the resulting product frame is easily removed from the matrix form 1 (2).

The design of the resulting product is quite durable and can withstand significant loads.

If necessary, the product can be cut with a diamond disk or drilled with a carbide-tipped drill.

The product is resistant to climatic factors.

The mass of the product covering the hatch with a diameter of 80 cm is 8–9 kilograms.

This allows anyone to easily transfer and install the product (artificial stone) in the right place or lift it and get to the object located under it - for example, the sewer manhole (Fig. 4).

In the normal position, the decorative covering element is located above the protected object, fitting into the surrounding landscape in a natural way (figure 5).

The proposed method allows for the industrial production of products that simulate natural stone.

Information sources

1. RF patent No. 2175913, IPC B28B 3/02, B28B 11/00, dated 03.09.1999.

2. RF patent No. 20845953, IPC E04C 1/40, dated 16.06.1992.

3. RF patent No. 79305, IPC M.C. E04C 2/26, B44C 5/04, dated June 26, 2008.

Claims (5)

1. A method of manufacturing products that simulate natural stone, including forming a convex matrix with a relief surface, forming a layer of glass mat, applying a binder layer of polyester resin with a hardener, and applying a layer of coarse sand and / or stone chips, characterized in that on the outer the surface of the mold is applied a separation layer with low adhesion to the material of the mold, on top of the separation layer is applied the first binder layer of a polyester resin with a hardener, to which is pressed full-time glass mat to copy the embossed surface of the mold, a second binder layer of polyester resin with a hardener is applied over the layer of piece glass mat to ensure that the polyester resin is embedded in the glass mat, air bubbles are removed from the binder layers by mechanical action, for example, with a roller and applied to the uncured second the bonding layer is coarse sand and stone chips with a particle size of 2-6 mm, after which they provide hardening of the bonding layers by heat and get CAS products, which are removed from the form template. 2. The method according to claim 1, characterized in that fractions of colored stone chips with a particle size of 1-3 mm are locally introduced into the uncured layer of coarse sand and stone chips to simulate granite spots and / or veins of mineral rocks. 3. The method according to claim 1, characterized in that the hardening of the binder layers is carried out at a temperature of from +10 to + 25 ° C for at least 24 hours 4. The method according to claim 1, characterized in that the hardening of the binder layers is carried out at a temperature below + 10 ° C for at least 72 hours 5. The method according to claim 1, characterized in that the product is subjected to exposure for post-hardening for 3 to 10 days.

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