SK189299A3 - IMITATION STONES FOR DECORATING BUILDING STRUCTURES AND A METHODì (54) FOR THE PRODUCTION THEREOF - Google Patents

Abstract

The invention relates to an imitation stone for decorating building structures which is comprised of three layers. One layer is discontinuous of the surface having different colorings and a thickness of 0-5 mm. A second layer is a continuous intermediate layer having only one color and a thickness of 2-5 mm. A third layer is a base and resistance inner layer having a thickness of 3-10 mm. The shape and coloring of the stone imitates those of natural stone. The first two layers have 28-48 wt. % polyester resin with reinforcers, or polyvinyl chloride or polystyrene optionally with the addition of cross-linking agents, 50-70 wt. % quartz powder and 2-10 wt. % pigments. The inner layer has 100 wt. % polyurethane foam with reinforcers or 20-35 wt. % fiber glass and 65-80 wt. % polyester resin with reinforcers. The imitation stone is produced in a rigid or flexible structure in which the mixture for the surface layer, the intermediate layer, and the base layer is successively applied by spraying or with a brush. The layers cure and combine with one another. The product is manually pulled out of the interior of the structure and the entire external surface is sandblasted. An additional method is comprised of applying a continuous layer of the curing base mixture on the inner surface of the structure. The mixture is manually pulled out and a continuous layer of the mixture having only one color is applied on the entire external surface of the layer. The mixture hardens and discontinuous mixtures for the surface layer having different colorings are applied over said continuous layer. The mixture hardens and the entire external surface is sandblasted.

Description

The invention relates to an imitation of natural stone having the shape, color and appearance of natural stone and can be used for interior and exterior decorative constructions such as fountains, rocks with waterfalls, in objects and devices incorporating imitation of natural stone structures for finishing ceilings, walls and floors. The invention also relates to a method for producing this imitation natural stone.

BACKGROUND OF THE INVENTION

It is known to produce stone, marble and granite tiles from small and / or chipped blocks, which is based on joining these materials by coating their edge surfaces with a polyester-based binder, which is colored to a suitable color of the rocks used. The binder consists of a 1: 1.7 mixture of resin and a rock powder, as well as an addition of cobalt naphthenate and methyl ethyl ketone peroxide. The strips are joined together by compression and then formed to the desired shape and dimensions (Romanian Patent No. 63416). The present invention uses natural materials for the implementation of cladding in the form of slabs and aims at the recovery of certain wastes.

Furthermore, a method for producing natural stone imitation is known, which is based on the treatment of an alkaline annealed blast furnace slag with pellets of 20 mm granules, obtained from dust collected from the flue gas while tempering ferroalloys, crumbled brick from the furnace and tar sludge. The various wastes which are recovered in this way yield a product which can replace concrete (Romanian Patent No. 73950).

The materials known from the prior art as stone replacements, which are used in construction sites, have a high weight, their transport is problematic and it is not possible to reproduce the shape and coloring of natural stones with them. Therefore, they are not suitable for decorative constructions. This has created the problem of providing a lightweight material which can be easily manufactured, transported and, above all, which has an indistinguishable appearance identical to natural stone.

SUMMARY OF THE INVENTION

The natural stone imitation of the present invention eliminates the drawbacks of known natural stone imitations by consisting of three layers, one discontinuous on the surface, with different colors and a thickness of 0 to 5 mm, one compact monochromatic interlayer with a thickness of 2-5 mm and one inner , which forms a durable backing layer and has a thickness of 3 to 10 mm, so that the artificial stone has the shape and color of the natural stone. The surface layer consists of 28 to 48% by weight of polyester resin with reinforcing agents or polyvinyl chloride or polystyrene, optionally with the addition of crosslinking agents, 50 to 70% by weight of silica flour and 2 to 10% by weight of pigments. The interlayer consists of 28 to 48% by weight of polyester resin with reinforcing agents or polyvinyl chloride or polystyrene, optionally with crosslinking agents, 50 to 70% by weight of silica flour and 2 to 10% by weight of pigments which determine the background color, while the inner layer consists of 100% or 20-35% by weight of glass fibers and 60-80% by weight of polyester resin with reinforcing agent.

A method of making a natural stone imitation (artificial stone) for decorative constructions according to the present invention is to apply a mixture to the surface layer in a rigid or flexible formation that mimics a natural stone by spraying or brushing on some of its internal parts. the prepared surface layer is allowed to solidify, then the entire interior surface is sprayed or brushed onto the intermediate layer and the mixture is left until it solidifies and is no longer united with the applied first layer and the inner surface thus obtained by spraying is applied In the case of a mixture of polyurethane with a reinforcing agent or by spraying or brushing, a continuous layer of the mixture based on polyester resin, reinforcing agent and glass fibers is applied and allowed to cure. This structure, made up of three solid, mutually integral layers joined together, is manually pulled out of the interior of a rigid or flexible formation, and finally the entire outer surface of the manufactured product is sandblasted.

Another method of making a natural stone imitation (artificial stone) for decorative constructions according to the present invention is to apply a continuous layer of a mixture of polyurethane with a reinforcing agent or spraying to a rigid or flexible formation that resembles the shape of a natural stone. or with a brush, apply a continuous layer of the blend based on polyester resin, reinforcing agent and glass fibers and allow to cure. The layer thus obtained is manually withdrawn from the rigid or flexible body and a continuous layer of a monochromatic mixture is formed by spraying or brushing on its entire outer surface until it is cured and then one layer of the mixture is intermittently applied to the surface. a layer of different coloration, this layer is allowed to cure, and finally the entire structure obtained from the three interconnected layers on its entire outer surface is sandblasted.

The advantages of the natural stone imitation according to the invention are as follows:

• because of their shape, appearance and coloring, which is given by pigments, they cannot be distinguished from natural stone;

• it is a lightweight product that can be easily transported and mounted in any location (walls, ceilings, floors, yards, etc.);

• has a very good mechanical, temperature and weather resistance in relation to its three-layer structure, so that it can be used for a very long time outdoors;

The artificial stones have such a shape that they can be laid very easily on top of one another in different arrangements, while maintaining the appearance of a rock or other natural phenomenon or, when flat, can be used for tiling.

The advantages of manufacturing a natural stone imitation according to the invention are as follows:

• the raw materials used are readily available;

• no special equipment is required, but only known spray guns, brushes and air spray guns are sufficient;

• manufacturing processes are very simple.

DETAILED DESCRIPTION OF THE INVENTION

The invention is explained below with reference to examples of making natural stone imitations for decorative constructions.

Example 1

A rigid body is made from one single piece or from several parts which are connected by conventional screws. The formation is obtained from polyester resin with reinforcing agent and glass fibers. It represents a form (negative) that mimics the shape of natural stone, but its upper surface is not completely enclosed. This form may be small, medium or large, depending on the type of construction to which the imitation of natural stone (artificial stone) is to be applied.

Mixtures containing 28 to 48 parts by weight of polyester reinforcing resin (added at the time of use), 50 to 70 parts by weight of silica flour and 2 to 10 parts by weight of coloring pigments compatible with the resin are prepared in multiple containers. . The mixtures vary according to the dye used and its amount, so that they have different colors and thus even different shades. They are made by simply mixing the resin with silica flour, pigments and finally with a reinforcing agent.

The rigid structure as a mold is placed in the position in which it is to be used, that is, through an opening facing upwards, but prior to its entire inner surface a layer of material (e.g. wax) is applied to facilitate later withdrawal of the product obtained. Then, a thin layer of the preformed mixture is sprayed onto some parts of the inner surface of the formation. Depending on the predetermined pattern of natural stone imitation, portions of this layer may have different shades that will appear in the final product as some scratches or depressions. The applied parts of the layer are of a thickness which, after curing, can reach places with a maximum thickness of up to 5 mm. After this first layer has cured, a continuous layer of one single, as in the previous case, a pre-blend that will determine the background color of the future imitation of natural stone is applied to the entire inner surface of the formation by another sprayer. Colors can range from white to dark gray, varying in color shades from gray or white to dark brown through different shades of cream or red, etc., as is the case with natural stones. After the second layer has cured, a third layer of polyurethane solution with a reinforcing agent is sprayed. After it has cured, when the mold has been made from several parts, the bolts connecting it are unscrewed and the mold is separated from the final product. When the mold is made in one piece, the obtained product is manually withdrawn from the mold. In both cases, sand is sprayed on the entire outer surface of these products under pressure by means of an air gun, thereby giving the product a natural stone appearance.

Instead of spraying, brushing may be used to form the first two layers. Instead of using the polyester resin solution used in the preparation of the interlayer and outer layer mixture, a polyvinyl chloride or polystyrene solution, optionally with the addition of a crosslinking agent, can be used in the same proportion to the weight.

Example 2

The procedure is the same as in Example 1, except that the mold used as the mold is flexible, is made of silicone rubber, consists of one part and does not need to be waxed or otherwise coated on its inner surface. In this case, the three-layer product can be easily pulled without being deformed because the rubber mold is elastic.

Example 3

The procedure is as in Examples 1 and 2, i.e. a rigid or flexible formation is used, but the inner third layer, which is applied by spraying or manually by brush, consists of 20 to 35 parts by weight of glass fibers and 65 to 80 parts by weight of polyester resin solution. hardener. This mixture is made easily by simply mixing the glass fibers with a resin solution and at the time of use with a reinforcing agent. The glass fibers may be in the form of fabric, fibers or chopped form.

Example 4

The procedure is as in any one of Examples 1, 2 or 3, i.e. using the same materials and the same procedures, but using rigid or flexible forms of suitable shapes and producing natural stone slabs or tiles adapted for a particular construction the entire outer layer of which is sandblasted.

The natural stone imitations of the present invention are solid products that do not exhibit any kind of toxicity and are environmentally friendly.

Solvents of polymers must be thoroughly removed during manufacture using the regulations in force where such substances are handled.

The natural stone imitations of the present invention, produced by any of the procedures of Examples 1, 2 or 3, can be arranged individually or assembled in groups together, they can differ from each other in different shapes (depending on the pattern used), as in nature. It is possible to create artificial rocks with or without waterfalls, caves, walls with unevenness, tanks with uneven walls and bottom, water meters or any other selected buildings in the interior of buildings or outdoors, which give the object the impression of natural landscape. Such creations are suitable for decoration of hotels, restaurants, clinics, houses and apartments, kindergartens, zoos and other interiors, eventually. parks, botanical gardens and zoos, villa yards, etc., because the natural stone imitation of the described invention is weatherproof and resistant even in conditions in variable weather areas (from summer to winter).

Another use of the natural stone imitation according to the invention is in framing some parts of furniture (bookcase, showcase, wall cabinet, etc.) in a decorative structure made of these artificial stones or in combination with other materials or products (e.g. stainless steel or other metal, glass, wood) to create interior or exterior design.

The board-shaped products of Example 4 may be used for cladding walls, ceilings, floors, some parts of furniture, or for any other purpose using natural stone boards.

Claims (4)

1. Natural stone imitation for decorative buildings, characterized in that it consists of three layers, one of which is intermittently on the outside, with different coloration and a thickness of 0 to 5 mm, the other being a compact monochromatic interlayer with a thickness of 2 to 5 mm and the third is a base resistant inner layer with a thickness of 3 to 10 mm, mimicking natural stone in shape and color. Natural stone imitation according to claim 1, characterized in that the surface layer consists of 28 to 48% by weight of polyester resin with reinforcing agents or polyvinyl chloride or polystyrene, optionally with the addition of crosslinking agents, 50 to 70% by weight of silica flour and 2 to 10% by weight. Pigments, the interlayer consists of 28 to 48% by weight of polyester resin with reinforcing agents or polyvinyl chloride or polystyrene optionally with the addition of crosslinking agents, 50 to 70% by weight of silica flour and 2 to 10% by weight of pigments which determine the background color while the inner layer consists of 100% by weight of polyurethane foam with reinforcing agent or 20 to 35% by weight of glass fibers and 60 to 80% by weight of polyester resin with reinforcing agent. 3. A method of making a natural stone imitation for decorative constructions according to claim 1, characterized in that a mixture intended for the surface layer is applied to the rigid or flexible formation which mimics the shape of the natural stone by spraying or brushing on some of its inner parts. then cure the entire inner surface by spraying or brushing and allow this layer to cure, thereby bonding to the cured portions of the first layer and spraying a continuous layer of polyurethane-reinforcing compound or spraying onto the inner surface , or by brushing a continuous layer of polyester resin, reinforcing agent, and glass fiber mixture which is allowed to cure and the structure formed from three solid interconnected layers is manually pulled from the interior of a rigid or flexible formation and tapered c) the entire outer surface of the product is sandblasted. A method of making a natural stone imitation for decorative constructions according to claim 1, characterized in that a continuous layer of a mixture of polyurethane with a reinforcing agent or spraying or by brush is applied to the entire inner surface by spraying on a rigid or flexible formation which mimics the shape of natural stone. a continuous layer of polyester resin, reinforcing agent and glass fiber, which is allowed to cure, the layer obtained is manually pulled from a rigid or flexible formation and a continuous layer of a monochromatic mixture is formed by spraying or brushing to form an intermediate layer and allowed to cure; then a mixture of the mixture intended for a surface layer of different coloration is applied unevenly, allowed to cure and finally the entire structure obtained from three interconnected layers on its entire outer surface is sandblasted.