WO2002094523A1 - 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 PDFInfo
- Publication number
- WO2002094523A1 WO2002094523A1 PCT/IB2002/001776 IB0201776W WO02094523A1 WO 2002094523 A1 WO2002094523 A1 WO 2002094523A1 IB 0201776 W IB0201776 W IB 0201776W WO 02094523 A1 WO02094523 A1 WO 02094523A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- panels
- different
- layer
- tiles
- carried out
- Prior art date
Links
- 238000000034 method Methods 0.000 title claims abstract description 19
- 229910052500 inorganic mineral Inorganic materials 0.000 title claims abstract description 17
- 239000011707 mineral Substances 0.000 title claims abstract description 17
- 229920005989 resin Polymers 0.000 claims abstract description 22
- 239000011347 resin Substances 0.000 claims abstract description 22
- 239000008187 granular material Substances 0.000 claims abstract description 18
- 229920001187 thermosetting polymer Polymers 0.000 claims abstract description 7
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 4
- 238000006116 polymerization reaction Methods 0.000 claims abstract description 3
- 230000002226 simultaneous effect Effects 0.000 claims abstract description 3
- 238000005054 agglomeration Methods 0.000 claims abstract 2
- 230000002776 aggregation Effects 0.000 claims abstract 2
- 239000011449 brick Substances 0.000 claims description 12
- 239000000463 material Substances 0.000 claims description 9
- 239000004033 plastic Substances 0.000 claims description 5
- 239000000843 powder Substances 0.000 claims description 5
- 238000005034 decoration Methods 0.000 claims description 4
- 230000000694 effects Effects 0.000 claims description 4
- 239000010438 granite Substances 0.000 claims description 4
- 238000009413 insulation Methods 0.000 claims description 4
- 239000004579 marble Substances 0.000 claims description 4
- 239000000919 ceramic Substances 0.000 claims description 3
- 210000003298 dental enamel Anatomy 0.000 claims description 3
- 239000002650 laminated plastic Substances 0.000 claims description 3
- 239000005995 Aluminium silicate Substances 0.000 claims description 2
- 239000000853 adhesive Substances 0.000 claims description 2
- 230000001070 adhesive effect Effects 0.000 claims description 2
- PZZYQPZGQPZBDN-UHFFFAOYSA-N aluminium silicate Chemical compound O=[Al]O[Si](=O)O[Al]=O PZZYQPZGQPZBDN-UHFFFAOYSA-N 0.000 claims description 2
- 229910000323 aluminium silicate Inorganic materials 0.000 claims description 2
- 235000012211 aluminium silicate Nutrition 0.000 claims description 2
- 239000011521 glass Substances 0.000 claims description 2
- 239000004005 microsphere Substances 0.000 claims description 2
- 239000000203 mixture Substances 0.000 claims description 2
- 229910001562 pearlite Inorganic materials 0.000 claims description 2
- 239000008262 pumice Substances 0.000 claims description 2
- 238000009408 flooring Methods 0.000 description 3
- 238000007906 compression Methods 0.000 description 2
- 238000005266 casting Methods 0.000 description 1
- 210000003477 cochlea Anatomy 0.000 description 1
- 238000005520 cutting process Methods 0.000 description 1
- 239000011152 fibreglass Substances 0.000 description 1
- 238000003754 machining Methods 0.000 description 1
- 238000005498 polishing Methods 0.000 description 1
- 238000003825 pressing Methods 0.000 description 1
- 239000011150 reinforced concrete Substances 0.000 description 1
- -1 resistant to fire Substances 0.000 description 1
- 230000003068 static effect Effects 0.000 description 1
- 239000002966 varnish Substances 0.000 description 1
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.
- a method presently used for carrying out said agglomerates consists in inserting granules mixed with the resin in forms, where they are heated and subject to high vibro-compression in order to achieve the hardening of the whole mass, which becomes an enbloc. Afterward the enbloc must be cut, smoothed and worked, for carrying out the desired elements.
- This method uses a low resin percentage, but requires presses and large dimension equipments, with consequent investments and high operational expenses. Moreover the cuts and the polishing of the raw plates produce large amount of powders and require long machining times.
- 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.
- figure 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
- figure 2 shows a top view of the plant of figure 1
- figures 3 and 4 show respectively a transversal section and a top view of a panel with brick superficial finish
- figures 5 and 6 show a transversal section and a top view of a panel with melaminic superficial finish
- figures 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 figure 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.
- 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 figure 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 figures 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.
- panels already having cuts can be carried out, such as, for instance, the cuts indicated with numeral 17 in figures 7 and 8.
- 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
- inner stiffening frames shaped panels with different thickness
- 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.
Abstract
Description
Claims
Priority Applications (5)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
CA002448075A CA2448075A1 (en) | 2001-05-24 | 2002-05-23 | Process for carrying out panels, tiles and the like using agglomerates of different minerals |
EP02733011A EP1395404A1 (en) | 2001-05-24 | 2002-05-23 | Process for carrying out panels, tiles and the like using agglomerates of different minerals |
JP2002591221A JP2005506263A (en) | 2001-05-24 | 2002-05-23 | Process to realize panels, tiles, etc. using different mineral agglomerates |
BR0210046-0A BR0210046A (en) | 2001-05-24 | 2002-05-23 | Process of making panels, tiles and similar products by using agglomerates of different minerals |
US10/478,906 US20040194421A1 (en) | 2001-05-24 | 2002-05-23 | Process for carrying out panels, tiles and the like using agglomerates of different minerals |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
ITPS2001A000017 | 2001-05-24 | ||
IT2001PS000017A ITPS20010017A1 (en) | 2001-05-24 | 2001-05-24 | PROCEDURE FOR OBTAINING TILES AND SIMILAR PANELS WITH VARIOUS MINERAL AGGLOMERATES AND POSSIBLE ADDITION OF RUBBER OR PLASTIC MATERIALS |
Publications (1)
Publication Number | Publication Date |
---|---|
WO2002094523A1 true WO2002094523A1 (en) | 2002-11-28 |
Family
ID=11453588
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
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 |
Country Status (7)
Country | Link |
---|---|
US (1) | US20040194421A1 (en) |
EP (1) | EP1395404A1 (en) |
JP (1) | JP2005506263A (en) |
BR (1) | BR0210046A (en) |
CA (1) | CA2448075A1 (en) |
IT (1) | ITPS20010017A1 (en) |
WO (1) | WO2002094523A1 (en) |
Cited By (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2009005384A2 (en) * | 2007-07-05 | 2009-01-08 | Labicer - Laboratório Industrial Cerâmico, S.A. | A process for the production of panels for cladding formed by a conglomerate of minerals and special aggregates mixed with two-component adhesive and/or thermosetting resins |
EP2942208A1 (en) * | 2014-05-09 | 2015-11-11 | Akzenta Paneele + Profile GmbH | Method for producing a decorated wall or floor panel |
US10350938B2 (en) | 2014-02-25 | 2019-07-16 | Akzenta Paneele + Profile Gmbh | Method for producing decorative panels |
US10618346B2 (en) | 2015-08-19 | 2020-04-14 | Akzenta Paneele + Profile Gmbh | Method for producing a decorated wall or floor panel |
Families Citing this family (12)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CA2681528C (en) | 2007-03-21 | 2018-10-23 | Ashtech Industries, Llc | Utility materials incorporating a microparticle matrix |
US8445101B2 (en) | 2007-03-21 | 2013-05-21 | Ashtech Industries, Llc | Sound attenuation building material and system |
US20090239429A1 (en) | 2007-03-21 | 2009-09-24 | Kipp Michael D | 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 |
US8074957B2 (en) | 2008-09-25 | 2011-12-13 | 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 |
US20160237704A1 (en) | 2015-02-14 | 2016-08-18 | Prime Forming & Construction Supplies, Inc., dba Fitzgerald Formliners | Formliners and methods of use |
EP3868536B1 (en) | 2015-12-28 | 2023-05-03 | Prime Forming & Construction Supplies, Inc., Dba Fitzgerald Formliners | Formliner for forming a pattern in curable material and method of assembling thereof |
CN107098705B (en) * | 2017-05-25 | 2019-12-13 | 佛山市东鹏陶瓷有限公司 | production method of transition layer composite foam ceramic plate |
CN107020682A (en) * | 2017-05-25 | 2017-08-08 | 佛山市东鹏陶瓷有限公司 | A kind of production method of composite foamed ceramic plate and its application |
KR102347229B1 (en) * | 2020-04-07 | 2022-01-04 | (주)알앰 | Method for manufacturing rubber terrazzo using crushed chip and rubber terrazzo manufactured by this manufacturing method |
Citations (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP0274702A1 (en) * | 1986-12-18 | 1988-07-20 | Sumitomo Metal Industries, Ltd. | Molding process and device therefor |
JPH0524151A (en) * | 1991-07-25 | 1993-02-02 | Toyoda Denken Kogyosho:Kk | Metal powder molded composite plate and manufacture thereof |
US5288353A (en) * | 1992-01-21 | 1994-02-22 | Deere & Company | Method for forming a polymeric plastic product having a hard wear-resistant surface |
Family Cites Families (6)
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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 |
CH507882A (en) * | 1967-12-06 | 1971-05-31 | Repla Sa | Process for the production of synthetic resin-bonded panels |
IT1117346B (en) * | 1977-04-22 | 1986-02-17 | Toncelli Marcello | PROCESS IMPROVEMENTS WITH COMBINED PRESSURE VIBRATION ACTION IN AIR-FREE ENVIRONMENT FOR FORMING GRAIN SHEETS LINKED WITH RESINS |
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 |
-
2001
- 2001-05-24 IT IT2001PS000017A patent/ITPS20010017A1/en unknown
-
2002
- 2002-05-23 BR BR0210046-0A patent/BR0210046A/en not_active Application Discontinuation
- 2002-05-23 WO PCT/IB2002/001776 patent/WO2002094523A1/en not_active Application Discontinuation
- 2002-05-23 JP JP2002591221A patent/JP2005506263A/en active Pending
- 2002-05-23 CA CA002448075A patent/CA2448075A1/en not_active Abandoned
- 2002-05-23 US US10/478,906 patent/US20040194421A1/en not_active Abandoned
- 2002-05-23 EP EP02733011A patent/EP1395404A1/en not_active Withdrawn
Patent Citations (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP0274702A1 (en) * | 1986-12-18 | 1988-07-20 | Sumitomo Metal Industries, Ltd. | Molding process and device therefor |
JPH0524151A (en) * | 1991-07-25 | 1993-02-02 | Toyoda Denken Kogyosho:Kk | Metal powder molded composite plate and manufacture thereof |
US5288353A (en) * | 1992-01-21 | 1994-02-22 | Deere & Company | Method for forming a polymeric plastic product having a hard wear-resistant surface |
Non-Patent Citations (1)
Title |
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PATENT ABSTRACTS OF JAPAN vol. 017, no. 300 (M - 1426) 8 June 1993 (1993-06-08) * |
Cited By (10)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2009005384A2 (en) * | 2007-07-05 | 2009-01-08 | Labicer - Laboratório Industrial Cerâmico, S.A. | A process for the production of panels for cladding formed by a conglomerate of minerals and special aggregates mixed with two-component adhesive and/or thermosetting resins |
WO2009005384A3 (en) * | 2007-07-05 | 2009-05-14 | Labicer Lab Ind Ceramico S A | A process for the production of panels for cladding formed by a conglomerate of minerals and special aggregates mixed with two-component adhesive and/or thermosetting resins |
US10350938B2 (en) | 2014-02-25 | 2019-07-16 | Akzenta Paneele + Profile Gmbh | Method for producing decorative panels |
US11117417B2 (en) | 2014-02-25 | 2021-09-14 | Akzenta Pancele + Profile GMBH | Method for producing decorative panels |
EP2942208A1 (en) * | 2014-05-09 | 2015-11-11 | Akzenta Paneele + Profile GmbH | Method for producing a decorated wall or floor panel |
WO2015169647A1 (en) * | 2014-05-09 | 2015-11-12 | Akzenta Paneele + Profile Gmbh | Method for producing a decorated wall or floor panel |
RU2647233C1 (en) * | 2014-05-09 | 2018-03-14 | Акцента Панееле + Профиле Гмбх | Method for manufacturing decorated wall or floor panel |
EP3403846A1 (en) * | 2014-05-09 | 2018-11-21 | Akzenta Paneele + Profile GmbH | Method for producing a decorated wall or floor panel |
US10479134B2 (en) | 2014-05-09 | 2019-11-19 | Akzenta Paneele + Profile Gmbh | Method for producing a decorated wall or floor panel |
US10618346B2 (en) | 2015-08-19 | 2020-04-14 | Akzenta Paneele + Profile Gmbh | Method for producing a decorated wall or floor panel |
Also Published As
Publication number | Publication date |
---|---|
JP2005506263A (en) | 2005-03-03 |
EP1395404A1 (en) | 2004-03-10 |
ITPS20010017A1 (en) | 2002-11-24 |
US20040194421A1 (en) | 2004-10-07 |
CA2448075A1 (en) | 2002-11-28 |
BR0210046A (en) | 2004-08-17 |
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