WO2001085642A1 - Process for making extrusions for producing multi-property tiles and obtained tiles - Google Patents

Process for making extrusions for producing multi-property tiles and obtained tiles Download PDF

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Publication number
WO2001085642A1
WO2001085642A1 PCT/IB2000/000621 IB0000621W WO0185642A1 WO 2001085642 A1 WO2001085642 A1 WO 2001085642A1 IB 0000621 W IB0000621 W IB 0000621W WO 0185642 A1 WO0185642 A1 WO 0185642A1
Authority
WO
WIPO (PCT)
Prior art keywords
varying
tiles
phase
extrusion
mixture
Prior art date
Application number
PCT/IB2000/000621
Other languages
French (fr)
Inventor
Francesco Coa
Original Assignee
Armonite S.P.A.
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 Armonite S.P.A. filed Critical Armonite S.P.A.
Priority to PCT/IB2000/000621 priority Critical patent/WO2001085642A1/en
Publication of WO2001085642A1 publication Critical patent/WO2001085642A1/en

Links

Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B28WORKING CEMENT, CLAY, OR STONE
    • B28BSHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B17/00Details of, or accessories for, apparatus for shaping the material; Auxiliary measures taken in connection with such shaping
    • B28B17/02Conditioning the material prior to shaping
    • B28B17/026Conditioning ceramic materials
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B28WORKING CEMENT, CLAY, OR STONE
    • B28CPREPARING CLAY; PRODUCING MIXTURES CONTAINING CLAY OR CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28C1/00Apparatus or methods for obtaining or processing clay
    • B28C1/10Apparatus or methods for obtaining or processing clay for processing clay-containing substances in non-fluid condition ; Plants
    • B28C1/14Apparatus or methods for obtaining or processing clay for processing clay-containing substances in non-fluid condition ; Plants specially adapted for homogenising, comminuting or conditioning clay in non-fluid condition or for separating undesired admixtures therefrom
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/30Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing magnesium cements or similar cements
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/30Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing magnesium cements or similar cements
    • C04B28/32Magnesium oxychloride cements, e.g. Sorel cement
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B9/00Magnesium cements or similar cements
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/00034Physico-chemical characteristics of the mixtures
    • C04B2111/00129Extrudable mixtures
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02WCLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
    • Y02W30/00Technologies for solid waste management
    • Y02W30/50Reuse, recycling or recovery technologies
    • Y02W30/91Use of waste materials as fillers for mortars or concrete

Abstract

Process for making extrusions for the creation of multi-property composite tiles having: 1) a phase of accurate dry mixing of the following materials: A) magnesium oxide varying form 40 % to 70 % B) silica, or quartz sand, varying from 10 % to 40 % C) calcium carbonate, in the form of powdered marble, varying form 5 % to 30 % D) sawdust, varying form 3 % to 30 % E) cellulose fibre, varying from 3 % to 10 % F) glass fibres, in a percentage ranging from 1 % to 5 %; G) talc, varying 1 % to 5 % H) pigments, varying 2 % to 5% II) a subsequent phase of complete mixing with a watery solution of magnesium chloride and magnesium sulphate. III) an extrusion phase at a determined speed IV) a cyclic cutting phase during which the extrusion is cut.

Description

DESCRI PTI ON
PROCESS FOR MAKING EXTRUSIONS FOR PRODUCING MULTI-PROPERTY TILES AND OBTAINED TILES
5 TECHNICAL FI ELD
This invention concerns a procedure for extrusion to be
used for making composite multi-property tiles and obtained tiles. BACKGROUND ART
10 As we know, right from the time of antiquity, man has been trying to create floor tiles that are durable, attractive, hygienic and economic. Thus many types of
tiles have been produced, including ceramic, artificial marble, cement and artificial stone ones. Many different
15 composites can be used in these types of tiles: Portland cement, white cement, clay, feldspar, quartz, silicofluoride, magnesium cement, dolomite etc. As a result of the many techniques, components and reagents used, tiles are produced with very different characteristics
20 in terms of: appearance, durability, electric conductivity,
porosity, weight, resistance to damage, natural radiation
and touch. All of these types of tiles have intrinsic characteristics, which make them attractive depending on the personal or architectural context in which they must be
25 evaluated. Just as every song has its own intrinsic beauty, which cannot be substituted by another harmony, every type of tile has its own appeal, its own intrinsic characteristics, even if its chemical composition
is similar to another. It only takes a few detai ls that appear insignificant, in the production process or in the blend of materials and reagents used, to give them new and surprising properties. So, when defining the properties of a tile we must take into consideration subtle aspects, delicate balances at a sublime level of perception, emotions that cannot be reasonably explained that draw not so much from the sphere of the aesthetically similar as from the complexities of electro-magnetic interference on the biological organism and on its implications on the laws that govern our psychic nature in general. The purpose of this invention is therefore to define a ti le that can be made through a skilful and careful blending of natural composites in the true sense of the word, combined in appropriate amounts. Another purpose is to define a tile, as above in which said composites are bound together will methods and means that will create a product that
expresses an ideal reconciliation between the properties of hardness, tenacity, porosity, smoothness and lightness. Another purpose is to define a tile that will dissipate electro-static charges in the environment. Another purpose is to define a ti le that will be able to significantly reduce sound waves. Another purpose is to define a tile with fireproof properties. Another purpose is to define a procedure that makes it possible to produce tiles economically. Another purpose is to define a procedure, as above, that makes it possible to produce very long tiles economically. Another purpose is to define a procedure, as above, that will make tiles with surfaces and/or edges that are shaped according to free, imaginative, aesthetic and/or functional lines. Another purpose is to define a production process that avoids the use of traditional pressing and/or tamping techniques inside specific moulds. DI SCLOSURE OF I NVENTION These and other purposes appear to be achieved by the procedure indicated in the main claim and that includes most of the following points. The preliminary phase consists in carefully blending the following composites in the granular or powder state that are present in the following percentages in weight. The technological
properties of each are known: their overall formulation, however, is new.
Magnesium oxide varying from 40% to 70%; this percentage is proportional ly suitable for giving the finished tile electric conductivity that will dissipate electro-static charges; silica, or quartz sand, varying from 10% to 40%, in proportion to the hardness you wish to give to the tile; calcium carbonate, in the form of powdered marble,
varying from 5% to 30%; sawdust, in compressed form, with granules of between
0.002mm and 2mm varying from 3% to 30%; cellulose fibre with a maximum length of 2mm, varying
from 3% to 10% glass fibres, broken up into lengths of a few millimetres, varying from 1 to 5%; talc, varying from 1 % to 5%; pigments, possibly iron oxide, following the known technology, varying from 2% to 10%. The powdery mixture specified above is then carefully mixed with a rotary-blade mixer, rotating at a low speed, in order to prevent the lighter and/or smaller particles from escaping into the air. When mixing has finished, the earth-like mixture is transferred to another mixing machine, which has a kneading function. A watery solution of magnesium chloride with a density ranging from 20 to
35 Baume degrees and magnesium sulphate with a density of between 5 and 25 Baume degrees is in fact pumped into the machine, through special nozzles, at a pressure of approximately 1 bar. These composites are present in respective proportions of 80/100% and 0/30%. The weight of this watery re-agent forms 30 to 70% of the weight of the total resulting mixture. The mixture is kneaded until it is completely blended. I mmediately after this it is transferred to a screw extruder that extrudes it through a die, which has the same section as the desired tile, after previously eliminating the gases contained in the mixture using well-know technological methods. The advantage of this die is that it not only gives the tiles the required level surface but various shapes and sizes of longitudinal scoring. This die can also be asymmetrical in order to give the typical rounded edge to slabs with an elongated shape used at the top of steps. At its extrusion mouth this die can also be used with one or more rollers that may be idle or operating at a rim speed synchronised with the extrusion speed, in order to create, on the top that wil l constitute the decorative surface of the tile,
transversal scoring, rustication, geometrical decorations and innumerable other shapes that can be obtained from the various ways of preparing the mixture laminated by
the extruder. These rollers could work together with a conveyor belt, instal led below, moving at the same speed as extrusion, and supporting the laminated mixture that has not yet hardened. These rollers could also replace the usual cutting technique using tight steel wires. Such a cutting process could in fact take place by "rotary die- cutting" the laminated substance below during formation, defining in this way the perimeter shape of the tile, which may be straight or shaped at opposite sides so that it can be embedded. Once the shape of the tile has been defined, it is left to consolidate in the air, where it hardens spontaneously during a period that varies from 4 to 12 hours, according to the percentages of the various substances used. Finally the product is transferred to weathering rooms where it stays for 24 hours at a temperature ranging from 20 to 60°C, derived also from the heat that escapes from the tiles themselves due to the exothermic reactions connected to their hardening process.

Claims

CLAI MS
I ) A procedure for making extrusions for creating multi- property tiles and obtained tiles with the following
characteristics: A phase of accurate, low speed dry mixing of the following materials in granular or powdery form in the following
percentages as to weight: magnesium oxide varying from 40% to 70% silica, or quartz sand, varying from 10% to 40% calcium carbonate, in the form of powdered marble, varying from 5% to 30% sawdust, in compressed form, with granules of between
0.002mm and 2mm varying from 3% to 30% cellulose fibre with a maximum length of 2mm, varying from 3% to 10%
glass fibres, broken up into lengths of a few millimetres, in a percentage ranging from 1 to 5%; talc, varying from 1 % to 5% pigments, possibly iron oxide, following the known technology, from 2% to 10%.
I I ) A subsequent phase of wet mixing in which the mixture
of point I ) above is kneaded in a rotary-blade mixer fitted with nozzles that spray a watery solution of magnesium chloride with a density ranging from 20 to 35 Baume degrees and magnesium sulphate with a density of between 5 and 25 Baume degrees onto the dry powdery mass at a pressure of approximately 1 bar. These composites are present in respective proportions of
80/100% and 0/30%. The weight of this watery re-agent forms 30 to 70% of the weight of the total resulting
mixture.
I I I ) an extrusion phase at a speed established according to the principles of the mixture as in points I ) and I I ) using the usual screw extruder that extrudes it through a die which has the same section as the desired tile, after previously eliminating the gases contained in the mixture using well-know technological method.
IV) a cyclic cutting phase during which the extrusion is cut to the desired length; V) a drying and hardening phase in an environment with a temperature ranging from between 20 and 60°C for a period of approximately 24 hours.
2) Procedure as in the previous claim characterised by the use of at least one roller at the outlet of the extrusion mouth so that said roller, with its rotary surface, shall impress lines and shapes defining the surface and/or the
perimeter of the tile resulting from the subsequent hardening, on the upper surface of the extrusion having a plastic consistency. 3) Tiles produced according to the procedure as in claims 1 and 2.
PCT/IB2000/000621 2000-05-10 2000-05-10 Process for making extrusions for producing multi-property tiles and obtained tiles WO2001085642A1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
PCT/IB2000/000621 WO2001085642A1 (en) 2000-05-10 2000-05-10 Process for making extrusions for producing multi-property tiles and obtained tiles

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
PCT/IB2000/000621 WO2001085642A1 (en) 2000-05-10 2000-05-10 Process for making extrusions for producing multi-property tiles and obtained tiles

Publications (1)

Publication Number Publication Date
WO2001085642A1 true WO2001085642A1 (en) 2001-11-15

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Cited By (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6676742B2 (en) * 2002-03-19 2004-01-13 Candis S.R.L. Mixture that can be added to decorative aqueous-phase paint products
EP1452504A2 (en) * 2003-02-05 2004-09-01 Maké, Charlotte Material for building elements, building elements obtained therewith and process for producing such building elements
WO2004099102A2 (en) * 2003-05-09 2004-11-18 Simem S.R.L. Composition for blocks for masonry and facing and method for their production
CN102191835A (en) * 2010-03-09 2011-09-21 霍炽坚 Manufacturing method of aluminum-plastic tile
CN102690101A (en) * 2011-03-24 2012-09-26 刘闽军 Waterborne inorganic chlorine magnesium synthetic process
CN104446314A (en) * 2014-11-04 2015-03-25 北京工业大学 Lightweight keel for fabricated external wall heat insulation system and preparation method of lightweight keel
CN106316339A (en) * 2016-08-24 2017-01-11 永仁承信钢结构制作中心 Glazed tile and preparing method thereof
CN106431173A (en) * 2016-09-30 2017-02-22 江苏建邦建材科技有限公司 Magnesium oxysulfate wall plate and fabrication method thereof
US20190330113A1 (en) * 2018-04-26 2019-10-31 MagneStone Limited Synthetic stone

Citations (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB228847A (en) * 1924-02-06 1925-10-26 Granitite Mfg Company Composition of matter hardened or capable of being hardened by metallic chlorides
GB321895A (en) * 1929-02-19 1929-11-21 Adolfo Bruno Improvements in or relating to tiles, bricks and the like
GB383779A (en) * 1932-01-05 1932-11-24 Frederick Waldemar Engholm An improved composition for the manufacture of artificial stone, wood substitutes, or the like
CH236553A (en) * 1944-08-03 1945-02-28 Ortelli Fernando A method of manufacturing a composition for forming coatings or molded articles.
FR2267993A1 (en) * 1974-04-19 1975-11-14 Duchamp Robert Fireproof building matl. capable of being moulded or trowelled - for prefabricated panels, pipes, floors, false tiles, toys, etc.
US4150185A (en) * 1974-11-05 1979-04-17 Joachim Zur Verth Building materials in the form of woodstone panels or sheets and processes for their production
SU1046100A1 (en) * 1982-06-08 1983-10-07 Управление Механизации N7 Треста "Строймеханизация-2" Главомскпромстроя Device for cutting plastic bar
CN1052545A (en) * 1989-12-14 1991-06-26 郭光增 Si-Mg compound stovepipe and manufacture craft thereof
CN1061584A (en) * 1990-11-22 1992-06-03 焦俊魁 The making method of inorganic imitation of ceramic products

Patent Citations (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB228847A (en) * 1924-02-06 1925-10-26 Granitite Mfg Company Composition of matter hardened or capable of being hardened by metallic chlorides
GB321895A (en) * 1929-02-19 1929-11-21 Adolfo Bruno Improvements in or relating to tiles, bricks and the like
GB383779A (en) * 1932-01-05 1932-11-24 Frederick Waldemar Engholm An improved composition for the manufacture of artificial stone, wood substitutes, or the like
CH236553A (en) * 1944-08-03 1945-02-28 Ortelli Fernando A method of manufacturing a composition for forming coatings or molded articles.
FR2267993A1 (en) * 1974-04-19 1975-11-14 Duchamp Robert Fireproof building matl. capable of being moulded or trowelled - for prefabricated panels, pipes, floors, false tiles, toys, etc.
US4150185A (en) * 1974-11-05 1979-04-17 Joachim Zur Verth Building materials in the form of woodstone panels or sheets and processes for their production
SU1046100A1 (en) * 1982-06-08 1983-10-07 Управление Механизации N7 Треста "Строймеханизация-2" Главомскпромстроя Device for cutting plastic bar
CN1052545A (en) * 1989-12-14 1991-06-26 郭光增 Si-Mg compound stovepipe and manufacture craft thereof
CN1061584A (en) * 1990-11-22 1992-06-03 焦俊魁 The making method of inorganic imitation of ceramic products

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DATABASE EPODOC EUROPEAN PATENT OFFICE, THE HAGUE, NL; XP002155353 *
DATABASE EPODOC EUROPEAN PATENT OFFICE, THE HAGUE, NL; XP002155354 *
DATABASE WPI Week 198425, Derwent World Patents Index; AN 1984-157225, XP002155355 *

Cited By (12)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6676742B2 (en) * 2002-03-19 2004-01-13 Candis S.R.L. Mixture that can be added to decorative aqueous-phase paint products
EP1452504A2 (en) * 2003-02-05 2004-09-01 Maké, Charlotte Material for building elements, building elements obtained therewith and process for producing such building elements
EP1452504A3 (en) * 2003-02-05 2005-10-26 Maké, Charlotte Material for building elements, building elements obtained therewith and process for producing such building elements
WO2004099102A2 (en) * 2003-05-09 2004-11-18 Simem S.R.L. Composition for blocks for masonry and facing and method for their production
WO2004099102A3 (en) * 2003-05-09 2005-03-24 Simem S R L Composition for blocks for masonry and facing and method for their production
CN102191835A (en) * 2010-03-09 2011-09-21 霍炽坚 Manufacturing method of aluminum-plastic tile
CN102690101A (en) * 2011-03-24 2012-09-26 刘闽军 Waterborne inorganic chlorine magnesium synthetic process
CN104446314A (en) * 2014-11-04 2015-03-25 北京工业大学 Lightweight keel for fabricated external wall heat insulation system and preparation method of lightweight keel
CN106316339A (en) * 2016-08-24 2017-01-11 永仁承信钢结构制作中心 Glazed tile and preparing method thereof
CN106431173A (en) * 2016-09-30 2017-02-22 江苏建邦建材科技有限公司 Magnesium oxysulfate wall plate and fabrication method thereof
US20190330113A1 (en) * 2018-04-26 2019-10-31 MagneStone Limited Synthetic stone
US10858290B2 (en) * 2018-04-26 2020-12-08 MagneStone Limited Synthetic stone

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