RU2460702C2 - Method to manufacture artificial stone - Google Patents

Abstract

FIELD: construction.

SUBSTANCE: method to manufacture an artificial stone includes application of a binder onto a prepared setup with a thin layer on the basis of a translucent polymer resin and a filler in the form of a granulated material, hardening of a composition and surface polishing. The specified resin is acrylic or non-saturated polyester resin. The filler in the form of a granite or marble crumb with dimensions of fragments from 1 to 4 mm is laid on a layer of a binder after its hardening to a gel-forming condition. After full hardening of the composition a colour substrate is applied on it from a mixture containing a binder, a material on the basis of glass fibre is laid and impregnated with a polyester resin.

EFFECT: improved operational and strength characteristics of products with reduction of consumed used materials.

4 cl, 1 tbl, 3 dwg

Description

The invention relates to the field of artificial stones and can be used in construction, small-scale architecture and design.

Traditional technologies for the manufacture of artificial stones under marble and granite use a crumb of inorganic filler with various sizes of fractions and a binder (matrix). Acrylic resin or unsaturated polyester resins are typically used as the base for the binder. The components are mixed and molded by molding, or by compression in the molds, or by smooth conveyor molding, as well as using vibro-compaction and evacuation. After curing the resulting mixture, its surface is ground or polished to obtain the final product.

To achieve various effects of the appearance of artificial stone, various dyes and solid fillers are often added to the resin mixture.

Injections are predominantly heavy and thick. Injection technology is used, as a rule, for flat products, such as countertops.

An example of a traditional technology for the manufacture of artificial stones is a method of manufacturing an artificial composite material, mainly stone, according to the patent of the Russian Federation No. 2071418, priority from 01/03/1992. The method includes sequential laying in the form of a filler of a large fraction, filling intergranular voids with a filler of smaller fractions through a perforated lid, vibration sealing of each fraction and subsequent impregnation with a binder. It is possible to combine in one block aggregates of metal and rubber, polymer and mineral, granite and limestone, foam rubber and shell rock, etc. As a binder, polymer resin, thermoplastic monomer, water glass, cement, gypsum, etc. are used.

The closest solution to the proposed method according to the achieved result is a method for producing artificial marble according to the patent of the Russian Federation No. 2371410, priority dated 12.12.2005. Artificial marble contains an inorganic filler, a binder consisting of acrylic or unsaturated polyester resin, and translucent crumb of artificial marble, the surface of which is treated with a coloring material. The constituent compositions are mixed and poured into a special form. The shape may be glass or in the form of a rectangular sheet of another material. The molded composition is then cured in a hot air oven. The cured composition is ground to expose the translucent portion of the artificial marble chips on the surface of the composition. The resulting marble provides a sparkling pattern that resembles marble adorned with precious stones.

The disadvantages of the above methods is the high consumption of materials used and insufficient strength, hardness and durability of the composition, which reduces the vandal resistance of the products.

The objective of the invention is to improve the operational and strength characteristics of products while reducing the consumption of materials used, and therefore the weight of the product, as well as improving the appearance of artificial stone, more consistent with the structure of natural stone.

The problem is solved by changing technological operations, as well as through the use of other materials. A method of manufacturing an artificial stone includes laying in a snap a binder based on inorganic resins and a filler in the form of crumbs, curing the composition and grinding the surface. In this case, a translucent binder is applied directly to the tooling with a thin layer, after it has cured to a gel state, the filler is laid in the form of crumbs with fragment sizes from 1 to 4 mm, after the composition has completely cured, a colored substrate is applied to it, the material based on fiberglass is laid and impregnated with polyester resin , and after curing it is polished.

A layer of translucent binder is applied to the snap by spraying, with a layer thickness of 1-2 mm.

The color substrate consists of the following components:

- binder 27-45%;

- organic dry mixture with a fraction size of from 0.001 to 0.005 mm 50-75%;

- dye 3-5%.

Organic granite and marble chips are used as a filler.

As dry organic mixtures, material from the series is used: microcalcite, gypsum, dry putty mixtures, etc.

Figure 1-3 presents examples of products manufactured by the proposed method.

The manufacturing technology of artificial stone is as follows.

Artificial stone is made in a snap. The equipment can be made of various materials (polyester, epoxy, aluminum, silicone-wixint) and can have a different shape: flat or figured. A translucent layer of a binder in the form of a gel based on inorganic resins, for example, from acrylic or unsaturated polyester resin, is applied to the prepared snap-in. Translucent gel is applied to the equipment by spraying, the layer thickness is 1-2 mm. This binder layer is used to identify the stone pattern and protect the organic inclusions of granite and marble chips from environmental influences and external damage. After curing the translucent layer to the state of gelation, a filler layer is applied to it, consisting of organic granite and marble chips, which ensures the adhesion of the filler to the binder. The filler crumb may be made of inorganic or organic material. The size of the filler fractions can be from 1 to 4 mm. The filler may contain fractions of the same size or a mixture of fractions of different sizes.

On a fully cured layer of composite materials, a colored substrate is applied in accordance with the color scheme of the previously used chips.

The substrate consists of the following components:

- binder 27-45%;

- organic dry mixture with a fraction size of from 0.001 to 0.005 mm 50-75%;

- dye 3-5%.

As dry mixes can be used: microcalcite, gypsum, dry putty mixtures, etc.

This substrate performs several functions:

- ensuring the strength of the product, structures;

- completeness and depth of the picture (granite);

- a decrease in the composition of the product of composite material in comparison with traditional technologies, which improves the environmental parameters of the products;

- light tightness.

Fiber-based material is laid on an uncured substrate and impregnated with a general purpose polyester resin.

This fiberglass-based material provides reinforcement for products. The use of fiberglass-based material enhances the structural strength of the product in the following parameters: tensile, bending, impact.

The resulting composition is cured and polished, while providing a pattern that mimics natural stone.

The proposed technology can significantly reduce the consumption of expensive inorganic materials from which the binder and aggregate chips are made. Traditional injection molding requires a significantly larger volume of binder, which is mixed with a crumb of filler, and then poured into a snap. In the proposed technology, the binder is used in a layer that is sprayed on a tooling and in a substrate where inorganic materials are diluted with cheaper dry mixtures.

Table 1 shows the comparative characteristics of the properties of artificial stone, depending on the manufacturing technology.

Table 1 Name of characteristic Manufacturing technology Proposed molding Traditional (casting, molding) Density (kg / m ³ ) 1400-1600 1800-2000 Tensile Strength, MPa 1700 40 Thermal conductivity at 20 ° С, W / m · (° С) 0.80 0.80 Hygroscopicity,% 0.5 1,0 Resistance to chemically aggressive environments, saline solutions racks racks

From this table it can be seen that artificial stone products made by the proposed technology are preferable to artificial stone products made by casting + molding technology.

The above technological process allows to achieve a number of positive qualities in comparison with traditional technologies (the use of plastic fillers, compression molding, molding):

- reduction in the amount of materials used;

- ease of processing and installation of products;

- low weight of products and structures;

- natural appearance;

- the depth of the picture (granite);

- the ability to correct defects;

- protection against fungal manifestations on organic material (crumbs);

- ease of operation.

This invention allows to produce products of complex and even closed shape, various colors and shades of natural stone. Products made using the proposed technology are thinner and lighter than products made using traditional technologies. The proposed technology allows to reduce the consumption of expensive inorganic composite materials, which allows to reduce the cost of products and increase their competitiveness.

Products manufactured using this technology can be operated both indoors and outdoors.

Claims (4)

1. A method of manufacturing an artificial stone, including applying to a prepared snap a thin layer of a binder based on a translucent polymer resin and a filler in the form of crumbs, curing the composition and grinding the surface, characterized in that the specified resin is used acrylic or unsaturated polyester resin, the filler in the form granite or marble chips with fragment sizes from 1 to 4 mm are laid on a binder layer after curing to a state of gelation, after complete curing ozitsii her colored substrate deposited from a mixture comprising a binder material is placed on the glass fiber and impregnated with polyester resin. 2. The method according to claim 1, characterized in that the layer of translucent binder is applied to the snap by spraying with a layer thickness of 1-2 mm 3. The method according to claim 1, characterized in that the color substrate consists of the following components,%:
binder 27-45 microcalcite or gypsum with a size of fractions from 0.001 to 0.005 mm 50-75 dye 3-5 4. The method according to claim 1, characterized in that the specified polyester resin is used as a binder.

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