WO2006001726A1

WO2006001726A1 - Decorative-facing thermoplastic sheet material

Info

Publication number: WO2006001726A1
Application number: PCT/RU2004/000411
Authority: WO
Inventors: Vladimir Ivanovich Petrivny
Original assignee: Vladimir Ivanovich Petrivny
Priority date: 2004-06-23
Filing date: 2004-10-19
Publication date: 2006-01-05
Also published as: RU2263030C1

Abstract

The invention relates to producing decorative facing materials for finishing (outside and interior) of rooms and buildings instead of natural and synthetic stones, bricks and wood. The inventive decorative facing material is made of different types of thermoplastics (polyethylene, polypropylene, ABC-plastic, polycarbonates etc) whose thickness ranges from 0.5 to 8 mm with the aid of a vacuum-forming machine by vacuum thermal forming of sheets which are heated by infrared heating up to the high-elastic state thereof for 0.5-15 minutes at a vacuum ranging from 0.34 to 1.0 MPa.

Description

Decorative facing material from sheet thermoplastic

Description

The invention relates to the manufacture of decorative panels for exterior cladding of buildings, buildings for commercial or industrial use to create small architectural forms, and can also be used for interior decoration.

State of the art

Various molded articles from polymers, for example from polymer melts, are widely known. Molding of products from polymer melts (injection molding, thermal vacuum molding and extrusion) occurs under conditions of high stresses, shear or drawing, which determine the orientation of macromolecules, which is the reason for the anisotropy of the mechanical properties of the finished products (Encyclopedia of Polymers. -T.2, p. 515 , 1972, M. Cow, Encycl.).

Known molded products from sheet and film polymers, in particular from thermoplastics. For the processing of materials in the form of sheets and films, pneumatic and vacuum forming, mechanical molding (mechanical drawing of a heated billet), stamping (die cutting) and various combined methods are used. When processing thermoplastics by pneumatic and vacuum molding methods, the preform is preheated to a highly elastic state; after giving the workpiece the necessary shape, the material is cooled; depending on the design of the heating device, heat radiation and

SUBSTITUTE SHEET (RULE 26) contact heating; depending on the nature of the location of the products in the form, negative, positive and complex methods of forming sheet and film thermoplastics are distinguished (edited by N.I. Basov “Plastics Processing Textbook”, M., Chemistry, 1985, p. 16).

Basically, the use of molded products from sheet thermoplastics was limited to household items, packaging, sanitary products, and non-essential body parts.

Description of known methods

From RU 2005632, a decorative building product in the form of a panel based on a binder is known to be used for finishing interior interiors of buildings. To increase the decorativeness of the product and reduce the energy and labor intensity of the process, the binder is separately sealed with solutions of dyes of at least two colors, mixed in parallel until granules are formed, which are then mixed together in layers, adding a shutter binder, applied to the molding surface and mechanically act on this layer, and after it is coated with a base layer, kept until the mass is cured and impregnated on the front surface of the molded product with a transparent adhesive. The manufacturing process of these panels, however, is quite time-consuming, and the panels themselves are heavy, which limits their widespread use in the manufacture of small architectural forms. A decorative element as a facing material is known from RU 2130836, 1999, containing particles of crushed stones of different types and sizes of fractions, mounted on a substrate of natural stone by means of an adhesive with the possibility of image formation, while particles of crushed stones have a size of from 0.1 up to 4 mm and interconnected. A method of manufacturing known plates consists in fixing on a substrate of natural stone an adhesive substance of crushed natural stones. In particular, a decorative facing plate is known containing particles of crushed rock-like materials fixed to the substrate by means of a binder, the substrate being made of pressed sheet material, rock-like materials have a particle size of 1 to 10 mm and are fixed on the substrate with the possibility of forming a continuous face layer by means of a binder, applied in an amount of 0.6-1.1 kg / m, forming an adhesive layer. Pressed sheet material is asbestos-cement sheet, fiber-cement sheet or cement-bonded particleboard with a thickness of 6-12 mm; for the formation of the facial layer using crushed natural stones, or artificial stones, or ceramic particles; the adhesive layer is made of a binder based on epoxy resin, or on an acrylic basis, or a polyester basis, or a polyurethane basis; the front layer after curing is painted with paints for outdoor use. (RU 2196052).

Known products provide high frost and weather resistance, however, they are difficult to manufacture and low-tech in the process of facing buildings with a large work surface. This is due to the fact that, using well-known solutions, it is possible to manufacture small-sized products, laying them on the outer surface is fraught with a number of technical difficulties, for example, when installing them, it is necessary to apply a binder to the treated surface with stringent weather and frost resistance requirements and certain conditions curing or, if the binder is rejected, the use of a large number and range of profile structures for assembling known plates in a panel. Substrate Fabrication large size leads to a sharp increase in waste, because natural stone, as a rule, has natural microdefects, for example, cracks, in addition, transportation and installation are complicated by their large mass and the limited capabilities of natural stone. Thus, the organization of mass production of known decorative facing products with high weather and frost resistance is complicated, to a greater extent, by the material of the substrate used.

From RU 2143443, facing sheet products from wastes of film polymeric materials are known, including film shredding, cleaning from dust and grease deposits, washing, drying, distribution and compaction of raw materials on the substrate before the finished product cures, while the washed shredded waste is subjected to additional grinding before drying and compression in the agglomerate with a propeller with simultaneous staining by introducing pigment dyes into the agglomerate, and after compaction of the film particles of a given size, dried at 100 - HO ⁰ C for 3-8 minutes, the resulting web with a density of 30-40 kg / m ^{3 is} heated in an oven at 160-180 ° C until melting and final shrinkage on the substrate, followed by pressing and cooling in the mold under pressure 2 - 10 kg / cm, while the finished polymer sheet is formed together with the substrate. Products with high consumer properties are obtained, and the problem of waste disposal is also solved at the same time, however, the manufacturing technology of these materials is quite complicated and time-consuming.

Thus, in particular, from RU 220 6583, molded articles with improved optical and physicomechanical properties based on polypropylene are known. Kaplej polypropylene (TU 2211-015-00203521-95) is mixed with the ingredients of the composition and technological additives at room temperature, followed by processing the mixture through the silk head of an OMU brand extruder into a sheet 1.5 mm thick and 585 * 1 wide mm

The melt of the polymer composition from the slit head is fed to a 3-roll calender, where the required film thickness is calibrated. After passing through the 3rd shaft, the cooling sheet in the free state is subjected to thermal vacuum molding.

Sheet products are molded on an OMU P25Y10 thermoforming machine at a speed of 16 cycles per minute, at an average temperature of 11-zone upper heating of the forming socket 439.5 ° С and the lower 10-zone -389 ° С. The thickness of the finished product is 0.2 mm

According to the technical nature of the claimed invention, the above technical solution is the closest, however, the obtained known molded products are intended mainly as packaging containers, protective packaging.

The technical task of the claimed invention is the production of decorative-facing material (product) from sheet thermoplastic imitating natural (natural) or artificial stone, various types of wood, brickwork with a relief-protruding front surface, which has increased hardness and wear resistance.

Summary of the invention, disclosure of the invention.

Thus, this invention relates to decorative facing material from thermoplastic sheet material, intended for the manufacture of architectural and construction products and structural elements - small architectural forms, for interior and exterior decoration interiors, simple to use, instead of products from natural decorative facing materials from stone, wood.

Thus, the technical task of the invention is the creation of decorative facing materials from sheet thermoplastic that simulate the texture and texture of the surfaces of natural and artificial ornamental stones, various types of wood, brickwork, expanding the decorative capabilities of finishing materials while improving their physical, mechanical and protective properties ( weather resistance, fire resistance, wear resistance). The specified technical problem is achieved by the fact that the decorative-facing material of sheet material (product) of sheet thermoplastic imitating natural or artificial stone, brickwork, various types of wood, having a relief-protruding pattern on the front surface, is obtained by thermo-vacuum molding of thermoplastics with a thickness of 0.5 to 8.0 mm, containing, if necessary, on the front surface a decorative protective polymer film, with a vacuum discharge of 0.3 - 1.0 MPa, heating them to high elast condition, in particular at 80 -200 ° C, using infrared heating for 1 to 15 minutes. On a vacuum molding machine containing a forming matrix having positive negative plastic molds with holes for supplying and discharging air from the cured filled epoxy composition, if necessary reinforced with a metal mesh during subsequent cooling with water sprayed on its surface or with air and, if necessary, painted with weather-resistant and fireproof paintwork material. In the claimed invention use sheets of thermoplastics such as

SUBSTITUTE SHEET (RULE 26) ABS plastics (impact resistant acrylonitrile butadiene styrene) made of polyethylene, polypropylene, polycarbonate, their copolymers, etc. Thermo-vacuum molding is carried out on a vacuum molding machine containing a matrix having negative-positive forms, in particular, multi-nest made of cured various epoxy or polyester compositions various metal powders (aluminum, iron, copper, etc.) mineral powders (diabase, marshalite, etc.) and reinforced with a metal mesh if necessary.

Sheets of thermoplastics (0.5 - 8 mm thick), if necessary (depending on the receipt of a particular decorative effect), have on the surface (on the front surface) a decorative protective polymer film, in particular based on acrylates, etc.

If necessary, depending on consumer properties and operating conditions, the resulting decorative-facing material can be painted with various weather-resistant and fire-resistant paints and varnishes, for example, water-based acrylic paints. Detailed Description of the Invention

In accordance with the claimed invention, a lightweight decorative facing material (product) is obtained from sheet thermoplastic for interior and exterior decoration of rooms and buildings, with a hard wear-resistant front surface having a relief-protruding pattern imitating natural or artificial stone (marble, granite, limestone, sandstone, etc.), brickwork, various types of wood.

The following examples illustrate the invention but do not limit it: Example 1.

SUBSTITUTE SHEET (RULE 26) A decorative-masonry material is obtained that imitates masonry from thermoplastic sheets of impact-resistant ABS plastic 2 mm thick on a vacuum forming machine, heating sheets of ABS thermoplastic to a highly elastic state; for example, up to 96 - 140 ⁰ C for 2 min (using infrared heating) under vacuum rarefaction of 0.5-0.6 MPa using a negative forming matrix from a cured metal-filled epoxy composition (filled with iron, etc.) reinforced with a metal mesh; the matrix has openings for supplying and discharging air.

The formed sheets are cooled with water sprayed on their surface and painted with, for example, water-dispersed acrylic paint.

The resulting decorative and facing material has a beautiful relief-protruding pattern imitating brickwork on the front surface. This material is very light, has a hard and wear-resistant front surface (does not scratch), is convenient to use when decorating the room and buildings.

The following is a technology for manufacturing it.

For example, a thermoplastic sheet (non-combustible, impact-resistant ABS plastic) is extruded. After extruding a sheet of thermoplastic, a protective and decorative polymer film with a pattern is rolled onto its surface when heated, or glued, in particular, an acrylic film.

The resulting material is fed to a vacuum molding machine, where it is subjected to molding, for example on a negative matrix.

Then the molded billet is sent to a punch press, where it is given a certain shape and edge size. Item Received

Subsequently, the product (with hollow cavities not on the front surface of the product) is filled (its cavities are hollow), for example, with some foam

SUBSTITUTE SHEET (RULE 26) material (polyurethane foam or other foam), which gives the product additional rigidity, heat insulation properties, increased fire resistance, soundproofing properties. Filling with a foam polymer is carried out either by directly filling the cavities with foam, or by inserting (inserting) the finished foam into the outer surface of the product.

Example 2.

Get decorative-facing material imitating marble for interior decoration similarly to example 1. To obtain it, sheets of polypropylene, painted in bulk, 3.0 mm thick are used.

The material is formed on a vacuum molding machine with a vacuum discharge of 0.6 MPa and heated to a highly elastic state. Using infrared heating for ~ 2.5 minutes. A positive forming matrix (with openings for supplying and discharging compressed air) is used from a cured, filled with aluminum powder polyester composition reinforced with a metal mesh.

The formed sheets are air cooled.

Example 3

Obtain decorative wood-cladding material from 1.5 mm thick thermoplastic polycarbonate sheet analogously to example 1 under the following molding conditions on a vacuum molding machine: the sheets are heated by infrared heating to a highly elastic state, for example, to 127 - 135 ⁰ C, for 2 x minutes and molded under vacuum discharge of 0.4 MPa.

Industrial applicability. The resulting decorative material has a low specific gravity (light), has a wear-resistant surface of the front layer; convenient to use.

The use of certain conditions of thermal vacuum molding (time, temperature, infrared heating) in combination leads to a more uniform temperature distribution on the surface, eliminates warping of products.

Thus, according to the invention, a lightweight building decorative and facing material with a diverse relief pattern, with increased wear resistance of the front surface and convenient to use (see Fig. 1 / 4-4 / 4) are obtained. At the same time, the entire building may be lined, or it can be used to highlight architectural elements, such as foundations, balconies and loggias, stairwells, pediments, arbors and flower boxes, swimming pools and fountains, grottoes and fences; during interior decoration, panels can be used as decorative elements giving special chic and piquancy to your interiors. Decorative cladding panels can be a great addition to traditional vinyl siding. In addition to the protective and decorative functions, siding allows you to hide the insulating material placed on the outside of the building. Unlike walls made of ordinary brick and stone, such a surface will not crack, crumble over time, in winter white salt stains will not appear on the wall. Using panels, you can successfully protect a construction brick from atmospheric influences, solve the problem of wall insulation or add new colors to the facade. Using the panels, you can avoid piling up stone and cement in the yard during installation work, you don’t have to worry about strengthening the foundation, which would inevitably have to be done when facing with natural or artificial stone, besides, the work would take a few days, and not

SUBSTITUTE SHEET (RULE 26) weeks and months. Without much effort, you can give the appearance of a stone palace to anyone, including a wooden structure.

Decorative and facing material meets the most stringent quality standards and is designed for a long service life. It is resistant to atmospheric and physical influences: it does not crack, does not crumble, does not fade in the sun, does not rot, does not corrode, and resists impact. It perfectly withstands the impact of weather vagaries of Russia, where hot summers are replaced by cold winters.

Claims

Claim

Decorative-facing material from sheet thermoplastic imitating natural or artificial stone, brickwork, various types of wood, having a relief-protruding pattern on the front surface, obtained by thermal vacuum molding of thermoplastics sheets with a thickness of 0.5-8 mm, containing, if necessary, decorative surfaces on the front surface - a protective polymer film, with a vacuum discharge of 0.3-1.0 MPa, when heated to a highly elastic state for 0.5-15 minutes using infrared heating on a vacuum form a caster containing a forming matrix having positive-negative forms, if necessary, multi-slotted with holes for supplying and removing air from the cured filled epoxy or polyester composition, if necessary reinforced with a metal mesh, followed by cooling of the finished material with water sprayed on its surface or air and, if necessary, painting with weatherproof and fireproof paintwork.