US20040194421A1 - Process for carrying out panels, tiles and the like using agglomerates of different minerals - Google Patents

Process for carrying out panels, tiles and the like using agglomerates of different minerals Download PDF

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Publication number
US20040194421A1
US20040194421A1 US10/478,906 US47890604A US2004194421A1 US 20040194421 A1 US20040194421 A1 US 20040194421A1 US 47890604 A US47890604 A US 47890604A US 2004194421 A1 US2004194421 A1 US 2004194421A1
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US
United States
Prior art keywords
panels
different
layer
tiles
carried out
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US10/478,906
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English (en)
Inventor
Max Canti
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Canti & Figli Srl
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Canti & Figli Srl
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Canti & Figli Srl filed Critical Canti & Figli Srl
Assigned to CANTI & FIGLI S.R.L. reassignment CANTI & FIGLI S.R.L. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: CANTI, MAX
Publication of US20040194421A1 publication Critical patent/US20040194421A1/en
Abandoned legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C67/00—Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00
    • B29C67/24—Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00 characterised by the choice of material
    • B29C67/242—Moulding mineral aggregates bonded with resin, e.g. resin concrete
    • B29C67/243—Moulding mineral aggregates bonded with resin, e.g. resin concrete for making articles of definite length
    • B29C67/244—Moulding mineral aggregates bonded with resin, e.g. resin concrete for making articles of definite length by vibrating the composition before or during moulding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B23/00—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects
    • B28B23/0081—Embedding aggregates to obtain particular properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B3/00—Producing shaped articles from the material by using presses; Presses specially adapted therefor
    • B28B3/02—Producing shaped articles from the material by using presses; Presses specially adapted therefor wherein a ram exerts pressure on the material in a moulding space; Ram heads of special form
    • B28B3/025—Hot pressing, e.g. of ceramic materials

Definitions

  • the present invention refers to a process allowing to carry out fire-proof, water-proof mechanical stress-proof panels, tiles and the like with different superficial finishes, fit for floorings and coverings generally.
  • the process includes also the elements carried out by said process.
  • Another method consists in forming plates having a defined thickness by positioning the powders mixed with resins into rubber trays or into belts with holding sides, and achieving the hardening of the whole mass by vacuum vibro-compression and following free baking in oven.
  • Another method currently used for carrying out the agglomerates consists in pouring the mixture of granules and resins into an open mold. In this case it is necessary to use a very large amount of resin, with consequent decrease of the mechanical strength and resistance to heat of the manufactured elements.
  • the objects of the present invention consist in carrying out fire-proof, water-proof and mechanical stress-proof panels, tiles and similar with finishes made of brickwork, melaminic, or of other types, also decorated with carvings or three-dimensional architectural elements, using means not excessively expensive and having a low resin percentage.
  • the manufactured elements can be advantageously used for floorings, staircases, coverings and furnitures generally, or also for surface of kitchens, tables, benches and similar. Adding rubber granules or recycled plastic materials, high characteristics of acoustic insulation are achieved, which allow using the panels also for floors of suspended or floating type, with suitable female-male connections.
  • the terracotta granules, or of other minerals are mixed with bi-component or thermosetting resins and distributed with a dosing device on a plan, in such a way to form a layer of desired thickness.
  • the layer is then inserted between the heated surfaces of a press, where the resin polymerizes, hardening by virtue of the simultaneous effect of pressure and heat.
  • the surfaces can be constituted by wastes of grinded bricks, to carrying out elements similar to the brick, or constituted by granules of different minerals, to carrying out marble or granite type finishes.
  • the surfaces can be also coated with melaminic sheets, or with ready laminated plastic, which are heat included into panels so manufactured already melaminic coated.
  • a stiffening frame can be added in the base portion of the layer.
  • FIG. 1 shows a side schematic view of a plant for carrying out panels, tiles and similar according to the process object of the present invention
  • FIG. 2 shows a top view of the plant of FIG. 1;
  • FIGS. 3 and 4 show respectively a transversal section and a top view of a panel with brick superficial finish
  • FIGS. 5 and 6 show a transversal section and a top view of a panel with melaminic superficial finish
  • FIGS. 7 and 8 show a transversal section and a top view of a panel with grooves creating a visible bricks effect
  • numeral 1 indicates a silo containing the granules of material to be agglomerated.
  • silos could be provided, containing different material, for instance granules or powders of brick wastes, granules of other minerals, rubber granules or recycled plastic materials.
  • the granules, positioned in the hopper 2 are transferred by a cochlea 3 into a mixer 4 , where they are mixed with bi-component or thermosetting resin.
  • the two components of the resin are introduced in the mixer 4 by means of pumps 5 and 6 and the ducts 7 and 8 , shown in FIG. 2.
  • the thermosetting resin is directly inserted into the granules.
  • the granules mixed with the resin are introduced in a dosing hopper 9 , which can translate over rails 10 in order to scatter a layer of agglomerate 11 on the belt 12 , provided with holding sides.
  • the scattered layer is therefore introduced in the press 13 , through the belt 12 .
  • the heated jaws of the press cause the polymerization of the thermosetting or bi-component resin: it is carried out a panel made of firmly bonded mineral agglomerates, with a low percentage of resin, resistant to fire, water, dirty and mechanical stresses.
  • the dosing hopper 9 can depose on the belt 12 another layer of agglomerates mixed with bi-component resin. At the pressure stop, by means of the belt 12 the completed panel is discharged and a new layer is loaded.
  • the static press can be substituted with a continuous press in order to eliminate the opening and closing dead time.
  • a follower cutting device must be provided at the press outlet for carrying out panels from a continuous panel.
  • the panels can be homogeneous, or with a superficial portion different from the base portion, as shown for instance in FIG. 3.
  • numeral 14 indicates the superficial portion
  • numeral 15 indicates the base portion.
  • the superficial portion 14 could be carried out with brick powder, to achieve a brick finishing.
  • the stamping superficial portion could be carried out also by agglomerating, with the same procedures, different mineral granules, in such a way to achieve a marble or granite type effect.
  • the base portion 15 may contain rubber granules or recycled plastic material, to confer to the panels suitable characteristics of flexibility and acoustic insulation.
  • a melaminic sheet 16 shown in FIGS. 5 and 6, which polymerizes at the same time with the agglomerate layer or a ready plastic laminate, for which the same agglomerate acts as adhesive, in such a way to carry out a panel already coated.
  • the panel can be afterwards finished on the surface with decorations and heat and cold ceramic enamels.
  • the panels used in the building, shipbuilding fields and can be fit for floorings, also floating, or inner or external coverings of large surfaces, simulating the effects of the visible bricks with varied decorative patterns.
  • the panels can be pantograph carved, for carrying out different throated, inclined or sloped connections, or straight or rounded grooves, or ornamental patterns. Deepening the incisions through a numerical control pantograph up to consume the whole rigid layer, the panels can be stick on curved surfaces, such as columns of reinforced concrete, internal spiral staircases, arcs and vaults generally. Grids of different shape and dimension can be carried out as well.
  • a stiffening frame made of fiberglass or other materials, to improve the mechanical characteristics of the panel.
  • the sandwich panel so carried out can be superficially calibrated using a sanding machine and superficially treated with wax or suitable varnishes or enamels and heat and cold ceramic decorations.
  • the panels can be cut, squared and predisposed for joints, in the same way of MDF panels.
  • agglomerating light minerals such as pumice, pearlite, aluminium silicate or hollow glass microspheres, with inner stiffening frames, shaped panels with different thickness can be carried out, with rusticated ashlars or other decorative elements, usable for false ceilings, for flame trap or other.
  • the dosing device could be fixed, or positioned on a mobile belt also during casting, for instance in case of continuous press.

Landscapes

  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Chemical & Material Sciences (AREA)
  • Structural Engineering (AREA)
  • Finishing Walls (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)
  • Laminated Bodies (AREA)
  • Floor Finish (AREA)
US10/478,906 2001-05-24 2002-05-23 Process for carrying out panels, tiles and the like using agglomerates of different minerals Abandoned US20040194421A1 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
IT2001PS000017A ITPS20010017A1 (it) 2001-05-24 2001-05-24 Procedimento atto ad ottenere pannelli piastrelle e simili con agglomerati minerali vari ed eventuale aggiunta di gomma o materie plastiche
ITPS2001A000017 2001-05-24
PCT/IB2002/001776 WO2002094523A1 (en) 2001-05-24 2002-05-23 Process for carrying out panels, tiles and the like using agglomerates of different minerals

Publications (1)

Publication Number Publication Date
US20040194421A1 true US20040194421A1 (en) 2004-10-07

Family

ID=11453588

Family Applications (1)

Application Number Title Priority Date Filing Date
US10/478,906 Abandoned US20040194421A1 (en) 2001-05-24 2002-05-23 Process for carrying out panels, tiles and the like using agglomerates of different minerals

Country Status (7)

Country Link
US (1) US20040194421A1 (enrdf_load_stackoverflow)
EP (1) EP1395404A1 (enrdf_load_stackoverflow)
JP (1) JP2005506263A (enrdf_load_stackoverflow)
BR (1) BR0210046A (enrdf_load_stackoverflow)
CA (1) CA2448075A1 (enrdf_load_stackoverflow)
IT (1) ITPS20010017A1 (enrdf_load_stackoverflow)
WO (1) WO2002094523A1 (enrdf_load_stackoverflow)

Cited By (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20090202810A1 (en) * 2008-02-13 2009-08-13 Microposite, Inc. Process and Machine for Manufacturing Lap Siding and the Product Made Thereby
US8349444B2 (en) 2007-03-21 2013-01-08 Ashtech Industries, Llc Utility materials incorporating a microparticle matrix
US8440296B2 (en) 2007-03-21 2013-05-14 Ashtech Industries, Llc Shear panel building material
US8445101B2 (en) 2007-03-21 2013-05-21 Ashtech Industries, Llc Sound attenuation building material and system
US8591677B2 (en) 2008-11-04 2013-11-26 Ashtech Industries, Llc Utility materials incorporating a microparticle matrix formed with a setting agent
USD791364S1 (en) 2014-09-25 2017-07-04 Prime Forming & Construction Supplies, Inc. Formliner
US10137598B2 (en) 2008-09-25 2018-11-27 Prime Forming & Construction Supplies, Inc. Formliner and method of use
US10406721B2 (en) 2015-12-28 2019-09-10 Prime Forming & Construction Supplies, Inc. Formliner for forming a pattern in curable material and method of use
US11274457B2 (en) 2015-02-14 2022-03-15 Prime Forming & Construction Supplies, Inc. Formliners and methods of use

Families Citing this family (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
PT103777A (pt) * 2007-07-05 2008-01-07 Labicer Lab Ind Ceramico S A Processo para a produção de painéis para revestimentos constituídos por um aglomerado de minerais e inertes qualificados misturados com adesivo bicomponente e ou resinas termoendurecedoras
EP2910385B1 (de) 2014-02-25 2018-01-17 Akzenta Paneele + Profile GmbH Verfahren zum Herstellen von Dekorpaneelen
EP2942208A1 (de) * 2014-05-09 2015-11-11 Akzenta Paneele + Profile GmbH Verfahren zur Herstellung eines dekorierten Wand- oder Bodenpaneels
PL3132945T3 (pl) 2015-08-19 2020-03-31 Akzenta Paneele + Profile Gmbh Sposób wytwarzania dekorowanego panelu ściennego lub podłogowego
CN107020682A (zh) * 2017-05-25 2017-08-08 佛山市东鹏陶瓷有限公司 一种复合泡沫陶瓷板的生产方法及其应用
CN107098705B (zh) * 2017-05-25 2019-12-13 佛山市东鹏陶瓷有限公司 一种过渡层复合泡沫陶瓷板的生产方法
KR102347229B1 (ko) * 2020-04-07 2022-01-04 (주)알앰 고무칩을 이용한 고무 테라조의 제조방법 및 이 제조방법에 의해 제조된 테라조 타일

Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3150032A (en) * 1956-06-25 1964-09-22 Rubenstein David Abuse resistant articles of manufacture and method of making
US3271917A (en) * 1959-06-12 1966-09-13 Rubenstein David Reinforced plastic constructions
US3574801A (en) * 1967-12-06 1971-04-13 Repla Sa Method for making panels of the artificial stone-type
US4204820A (en) * 1977-04-22 1980-05-27 Marcello Toncelli Slab forming conveying line
US4956030A (en) * 1988-08-18 1990-09-11 Academy Of Applied Science Method of fabricating simulated stone surfaces and improved simulated stone products
US6709717B2 (en) * 1998-06-09 2004-03-23 Margrace Enterprises, Inc. Method for making polymer surfaced composites

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Publication number Priority date Publication date Assignee Title
US4874564A (en) * 1986-12-18 1989-10-17 Sumitomo Metal Industries, Ltd. Molding process and device therefor
JP2634508B2 (ja) * 1991-07-25 1997-07-30 株式会社豊田電研工業所 エレベーター用成形板及びその製造方法
US5288353A (en) * 1992-01-21 1994-02-22 Deere & Company Method for forming a polymeric plastic product having a hard wear-resistant surface

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3150032A (en) * 1956-06-25 1964-09-22 Rubenstein David Abuse resistant articles of manufacture and method of making
US3271917A (en) * 1959-06-12 1966-09-13 Rubenstein David Reinforced plastic constructions
US3574801A (en) * 1967-12-06 1971-04-13 Repla Sa Method for making panels of the artificial stone-type
US4204820A (en) * 1977-04-22 1980-05-27 Marcello Toncelli Slab forming conveying line
US4956030A (en) * 1988-08-18 1990-09-11 Academy Of Applied Science Method of fabricating simulated stone surfaces and improved simulated stone products
US6709717B2 (en) * 1998-06-09 2004-03-23 Margrace Enterprises, Inc. Method for making polymer surfaced composites

Cited By (15)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US8997924B2 (en) 2007-03-21 2015-04-07 Ashtech Industries, Llc Utility materials incorporating a microparticle matrix
US9076428B2 (en) 2007-03-21 2015-07-07 Ashtech Industries, Llc Sound attenuation building material and system
US8349444B2 (en) 2007-03-21 2013-01-08 Ashtech Industries, Llc Utility materials incorporating a microparticle matrix
US8440296B2 (en) 2007-03-21 2013-05-14 Ashtech Industries, Llc Shear panel building material
US8445101B2 (en) 2007-03-21 2013-05-21 Ashtech Industries, Llc Sound attenuation building material and system
US8110132B2 (en) * 2008-02-13 2012-02-07 James Hardie Technology Limited Process and machine for manufacturing lap siding and the product made thereby
US20090202810A1 (en) * 2008-02-13 2009-08-13 Microposite, Inc. Process and Machine for Manufacturing Lap Siding and the Product Made Thereby
US10137598B2 (en) 2008-09-25 2018-11-27 Prime Forming & Construction Supplies, Inc. Formliner and method of use
US10723040B2 (en) 2008-09-25 2020-07-28 Prime Forming & Construction Supplies, Inc. Formliner and method of use
US8591677B2 (en) 2008-11-04 2013-11-26 Ashtech Industries, Llc Utility materials incorporating a microparticle matrix formed with a setting agent
USD791364S1 (en) 2014-09-25 2017-07-04 Prime Forming & Construction Supplies, Inc. Formliner
US11274457B2 (en) 2015-02-14 2022-03-15 Prime Forming & Construction Supplies, Inc. Formliners and methods of use
US10406721B2 (en) 2015-12-28 2019-09-10 Prime Forming & Construction Supplies, Inc. Formliner for forming a pattern in curable material and method of use
US11027455B2 (en) 2015-12-28 2021-06-08 Prime Forming & Construction Supplies, Inc. Formliner for forming a pattern in curable material and method of use
US11725402B2 (en) 2015-12-28 2023-08-15 Prime Forming & Construction Supplies, Inc. Formliner for forming a pattern in curable material and method of use

Also Published As

Publication number Publication date
ITPS20010017A1 (it) 2002-11-24
JP2005506263A (ja) 2005-03-03
BR0210046A (pt) 2004-08-17
WO2002094523A1 (en) 2002-11-28
CA2448075A1 (en) 2002-11-28
EP1395404A1 (en) 2004-03-10

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Legal Events

Date Code Title Description
AS Assignment

Owner name: CANTI & FIGLI S.R.L., ITALY

Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:CANTI, MAX;REEL/FRAME:015496/0684

Effective date: 20031114

STCB Information on status: application discontinuation

Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION