WO2006013589A1 - Tray-shaped mould made of a vulcanized composite material - Google Patents

Tray-shaped mould made of a vulcanized composite material Download PDF

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Publication number
WO2006013589A1
WO2006013589A1 PCT/IT2004/000445 IT2004000445W WO2006013589A1 WO 2006013589 A1 WO2006013589 A1 WO 2006013589A1 IT 2004000445 W IT2004000445 W IT 2004000445W WO 2006013589 A1 WO2006013589 A1 WO 2006013589A1
Authority
WO
WIPO (PCT)
Prior art keywords
tray
layers
mould
shaped mould
rubber
Prior art date
Application number
PCT/IT2004/000445
Other languages
French (fr)
Inventor
Dario Toncelli
Original Assignee
Dario Toncelli
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 Dario Toncelli filed Critical Dario Toncelli
Priority to PCT/IT2004/000445 priority Critical patent/WO2006013589A1/en
Publication of WO2006013589A1 publication Critical patent/WO2006013589A1/en

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Classifications

    • 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
    • B28B7/00—Moulds; Cores; Mandrels
    • B28B7/34—Moulds, cores, or mandrels of special material, e.g. destructible materials
    • B28B7/348—Moulds, cores, or mandrels of special material, e.g. destructible materials of plastic material or rubber
    • 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

Definitions

  • the present invention relates to a tray-shaped mould made with a new rubber- based composite material.
  • a tray-shaped mould made with a new rubber- based composite material.
  • the said steps are performed in different stations, which causes the mould to be transferred, by means of translational motions, along the plant for the manufacture of the slabs.
  • the tray-shaped moulds used hitherto are made of a composite material in the form of a sandwich consisting of several layers of rubber and one or more layers of fabric arranged internally and so as to line the external surface of the mould and in particular the bottom surface of the mould.
  • the rubber is preferably a synthetic rubber chosen from among the rubbers resistant to temperatures utilized in order to bake or harden the slab formed in the mould. These rubbers must also be chemically resistant to the components of the mix which is poured into the mould.
  • the rubber used hitherto for the manufacture of tray-shaped moulds has been either a rubber called EPM (namely a terpolymer obtained from ethylene and propylene monomers) or an EPDM (namely a terpolymer obtained from monomers of ethylene, polypropylene and at least one third monomer consisting of an unconjugated diene).
  • EPM namely a terpolymer obtained from ethylene and propylene monomers
  • EPDM namely a terpolymer obtained from monomers of ethylene, polypropylene and at least one third monomer consisting of an unconjugated diene
  • the main problem consisted in the low adhesiveness of the EPDM rubber ⁇ with respect to the underlying fabrics.
  • the main object of the present invention is that of solving the abovementioned problems and drawbacks and in particular providing a tray-shaped mould made with a composite material of an elastomeric nature which is formed with components which are resistant to the high process temperatures, is dimensionally and geometrically stable and has at least one surface, preferably the outer surface, with a very low coefficient of friction.
  • the composite material comprises a layer based on gkssfibre which is arranged in between two layers of synthetic rubber, the said layer of based on gkssfibre having a structure permitting the rubber to flow and therefore to mix up.
  • the composite material with which the mould is made also comprises a cotton gauze which is applied onto the outer surface of bottom wall of the mould.
  • the number of rubber layers of a glassfibre-based structure arranged in between is chosen depending on other desirable characteristics of the mould, consequently of final composite material, which is vulcanized, mainly depending on the desired rigidity of the end product.
  • an optimum composite material was found to be one comprising three layers of rubber with two layers of a glassfibre-based structure arranged in between in an alternating arrangement, the said glassfibre-based structure being either an open-mesh netting or a mat.
  • a mould made with a composite material comprising only two layers of rubber with a glassfibre-based structure arranged in between would be of a much too low stiffness with the result that, particularly as a consequence of the compaction steps with application of a vibratory movement, the slab would have an undulate surface or at any rate not perfectly flat, so as to requite additional sizing and/ or smoothing operations.
  • the vulcanized composite material is formed by three layers of EPM or EPDM rubber with the alternating arrangement in between of two layers of either a mat or an open-mesh netting of glassfibre.
  • the tray-shaped moulds of the present invention which are intended to resist high temperatures and to the action of any corrosive components, are made with a composite material comprising rubbers of the EPM or
  • each rubber layer is in the order of a few millimetres, starting from a minimum thickness of 1 mm.
  • the glassfibre based structure can be either in form of a mat or of a netting of the open-mesh type, as already mentioned, so as to allow the rubber of the two layers between which the netting is arranged to pass through and therefore to mix up, since the adhesion of glassfibre to the rubber is very poor, if not close to zero.
  • the size of the meshes is at least 4 x 4 mm ⁇ even larger sizes obviously also being possible, in accordance with the desired effect.
  • this characteristic feature is obtained by impregnating the outer surface of the bottom wall of the tray-shaped mould with a cotton gauze able to withstand up to 200 0 C. Since adhesion of rubber to cotton also is very poor, the fluid rubber must pass through the meshes of the gauze, thus allowing a mechanical bonding.
  • the various constituent layers are arranged on top of each other staffing from the layer of cotton gauze: a first layer of rubber is arranged thereon, followed by the glassfibre- based structure in form either of a mat or a netting, and by a second layer of rubber.
  • a new glassfibre-based structure and then a layer of rubber are arranged, and so on, until a stack is formed consisting of the desired number of rubber layers spaced with glassfibre-based structures (either mats or open-mesh nettings).
  • the stack thus formed is then introduced into a conventional vulcanization press where a pressure in the order of 30-60 kg/ cm 2 for a few tens of minutes and a heating temperature of the pressing plates (as required by the vulcanization of the rubber forming the aforementioned layers) are applied, the said temperature being of about 170°C in the case of an EPM or EPDM rubber.
  • the inner surface is formed by a vulcanized rubber of the desired chemical and physical properties
  • - the outer surface, particularly at the bottom wall of the mould, is formed by the layer of cotton gauze which is of a low coefficient of friction and bonded to the overlying rubber
  • the composite material is entirely formed by elements resistant to high temperatures; - .
  • the mould is dimensionally stable, since the glassfibre-based structures (mats or nettings) do not undergo any dimensional modification at high temperatures;
  • the glassfibre is well bonded to the rubber without a need for the glassfibre to be preliminarily treated with, additives adapted to improve its adhesion, owing to the possibility given to the rubber to flow through the the glassfibre-based structures and to mix up..
  • FIG. 1 shows a typical tray-shaped mould used for the manufacture of slabs of conglomerate stone material
  • FIG. 2 shows a cross-section of the bottom wall of a tray-shaped mould made in accordance with, the present invention.
  • the mould 10 of figure 1 has a rectangular or square shape with a bottom wall 12 and the peripheral edges of the sidewall 14 turned outwards.
  • the composite material used for the mould of the invention consists of the following components: - three layers of synthetic rubber, identified by the reference numbers Ia, Ib and Ic;

Abstract

The invention refers to a tray-shaped mould (10) used for the manufacture of slabs of conglomerate stone material. The mould is made with a composite material in which a layer of a glassfibre-structure (2a, 2b) can either be a mat or an open-mesh netting. At least on the outer surface of the bottom wall (12) of the mould (10) a cotton gauze (3) is preferably applied. In order to be usable the composite material is subjected to hot pressure vulcanization.

Description

"Tray-shaped mould made of a vulcanized composite material11
Description
The present invention relates to a tray-shaped mould made with a new rubber- based composite material. Although such type of mould can be used in different industrial applications, a: specific reference is here made to the manufacture of slabs of conglomerate stone material.
In recent years technologies for the manufacture of thin and large-size articles in the form of slabs (up to 3.10 x 1.40 metres) have become more established on an industrial level, wherein a mix consisting of a natural stone material in the form of granulate or sand, or a ceramic material, also in the form of granulate of predefined particle size, and a binder, is deposited in a tray-shaped mould which is subjected to a compaction step accompanied by application of a vibrating movement and finally to a hardening step which in some cases envisages the baking of the "raw" article contained in the tray-shaped mould and in other cases hardening of the binder, for example in the case of a synthetic resin such as a polyester resin, through the action of heat and/ or a catalyst. As a rule, the said steps are performed in different stations, which causes the mould to be transferred, by means of translational motions, along the plant for the manufacture of the slabs. The tray-shaped moulds used hitherto are made of a composite material in the form of a sandwich consisting of several layers of rubber and one or more layers of fabric arranged internally and so as to line the external surface of the mould and in particular the bottom surface of the mould.
As regards the rubber, it is preferably a synthetic rubber chosen from among the rubbers resistant to temperatures utilized in order to bake or harden the slab formed in the mould. These rubbers must also be chemically resistant to the components of the mix which is poured into the mould.
Preferably the rubber used hitherto for the manufacture of tray-shaped moulds has been either a rubber called EPM (namely a terpolymer obtained from ethylene and propylene monomers) or an EPDM (namely a terpolymer obtained from monomers of ethylene, polypropylene and at least one third monomer consisting of an unconjugated diene).
As regards on the other hand the fabrics used together with the rubber in order to form the bottom of the tray-shaped mould - said fabrics in addition to forming a kind of reinforcement also favouring sliding of the mould during transfer thereof along the plant - they have hitherto been made of polyester fibre and/or polyamide fibre. During manufacture of the composite materials mentioned above, the main problem consisted in the low adhesiveness of the EPDM rubber ■with respect to the underlying fabrics.
In order to overcome this drawback, different measures have been adopted such as the application of primer based on resorcinol and formaldehyde to the interface between rubber and fabric, with the arrangement in between of a so-called adhesive "liner" based on butadiene rubber, which has a high degree of adhesiveness.
However this latter solution, which ensures a good adhesion between EPDM rubber and fabrics, also has further drawbacks, namely firstly the low resistance of the butadiene rubber forming the liner to high temperatures and secondly the large degree of shrinkage of the polyester fabrics since prolonged use of the mould at a high temperature results in a not insignificant dimensional variation thereof.
The main object of the present invention is that of solving the abovementioned problems and drawbacks and in particular providing a tray-shaped mould made with a composite material of an elastomeric nature which is formed with components which are resistant to the high process temperatures, is dimensionally and geometrically stable and has at least one surface, preferably the outer surface, with a very low coefficient of friction. More specifically, the composite material comprises a layer based on gkssfibre which is arranged in between two layers of synthetic rubber, the said layer of based on gkssfibre having a structure permitting the rubber to flow and therefore to mix up.
Similar composite materials are per se already known from the following patents : GB-A-I 382 486, where it is provided for preliminarily treating the gkssfibre with agents suitable to improve its bonding to the rubber; GB-A-I 467 470, where the gkssfibre is a network of strands arranged side by side and in a zig-zag form; FR-A-2 657 293, where the strands of gkssfibre are carded and consequently in alignment.
No one of said patents, however, the object is using the composite materials for making a tray-shaped mould.
This object and other objects of the present invention are achieved by a tray- shaped mould as defined in the appended claims.
In a preferred embodiment, the composite material with which the mould is made also comprises a cotton gauze which is applied onto the outer surface of bottom wall of the mould. The number of rubber layers of a glassfibre-based structure arranged in between is chosen depending on other desirable characteristics of the mould, consequently of final composite material, which is vulcanized, mainly depending on the desired rigidity of the end product.
In particular, an optimum composite material was found to be one comprising three layers of rubber with two layers of a glassfibre-based structure arranged in between in an alternating arrangement, the said glassfibre-based structure being either an open-mesh netting or a mat.
Actually, in case of a tray-shaped mould utilized in the manufacturing process of a conglomerate slab, a mould made with a composite material comprising only two layers of rubber with a glassfibre-based structure arranged in between would be of a much too low stiffness with the result that, particularly as a consequence of the compaction steps with application of a vibratory movement, the slab would have an undulate surface or at any rate not perfectly flat, so as to requite additional sizing and/ or smoothing operations. These drawbacks do not arise if the vulcanized composite material is formed by three layers of EPM or EPDM rubber with the alternating arrangement in between of two layers of either a mat or an open-mesh netting of glassfibre.
As already mentioned, the tray-shaped moulds of the present invention which are intended to resist high temperatures and to the action of any corrosive components, are made with a composite material comprising rubbers of the EPM or
EPDM type.
The thickness of each rubber layer is in the order of a few millimetres, starting from a minimum thickness of 1 mm.
In turn, the glassfibre based structure can be either in form of a mat or of a netting of the open-mesh type, as already mentioned, so as to allow the rubber of the two layers between which the netting is arranged to pass through and therefore to mix up, since the adhesion of glassfibre to the rubber is very poor, if not close to zero.
For this reason, when a netting of the open-mesh type is used, the size of the meshes is at least 4 x 4 mm^ even larger sizes obviously also being possible, in accordance with the desired effect.
As regards the desired low coefficient of friction of at least one surface of the composite material, this characteristic feature is obtained by impregnating the outer surface of the bottom wall of the tray-shaped mould with a cotton gauze able to withstand up to 2000C. Since adhesion of rubber to cotton also is very poor, the fluid rubber must pass through the meshes of the gauze, thus allowing a mechanical bonding.
In order to form the composite material according to the present invention, the various constituent layers are arranged on top of each other staffing from the layer of cotton gauze: a first layer of rubber is arranged thereon, followed by the glassfibre- based structure in form either of a mat or a netting, and by a second layer of rubber.
If so required, on top of this layer of rubber a new glassfibre-based structure and then a layer of rubber are arranged, and so on, until a stack is formed consisting of the desired number of rubber layers spaced with glassfibre-based structures (either mats or open-mesh nettings).
The stack thus formed is then introduced into a conventional vulcanization press where a pressure in the order of 30-60 kg/ cm2 for a few tens of minutes and a heating temperature of the pressing plates (as required by the vulcanization of the rubber forming the aforementioned layers) are applied, the said temperature being of about 170°C in the case of an EPM or EPDM rubber.
The resultant tray-shaped mould shows the following advantageous features:
- the inner surface is formed by a vulcanized rubber of the desired chemical and physical properties; - the outer surface, particularly at the bottom wall of the mould, is formed by the layer of cotton gauze which is of a low coefficient of friction and bonded to the overlying rubber;
- the composite material is entirely formed by elements resistant to high temperatures; - . the mould is dimensionally stable, since the glassfibre-based structures (mats or nettings) do not undergo any dimensional modification at high temperatures;
- the glassfibre is well bonded to the rubber without a need for the glassfibre to be preliminarily treated with, additives adapted to improve its adhesion, owing to the possibility given to the rubber to flow through the the glassfibre-based structures and to mix up..
The invention will be better understood and appreciated on the basis of the following description of a preferred though not unique embodiment with a reference to the attached drawing where :
- figure 1 shows a typical tray-shaped mould used for the manufacture of slabs of conglomerate stone material;
- figure 2 shows a cross-section of the bottom wall of a tray-shaped mould made in accordance with, the present invention.
The mould 10 of figure 1 has a rectangular or square shape with a bottom wall 12 and the peripheral edges of the sidewall 14 turned outwards.
It can be easily appreciated from figure 2 that the composite material used for the mould of the invention consists of the following components: - three layers of synthetic rubber, identified by the reference numbers Ia, Ib and Ic;
- two layers of glassfibre-based structures (either mats or nettings), identified by the reference numbers 2a and 2b;
- one layer of cotton gauze, identified by the reference number 3. It has been found that a tray-shaped mould made with the composite material of the present invention is no longer subject to shrinkage and may be reused up to the occurrence of mechanical breakages or superficial deteriorations of the rubber in contact with the material deposited into the mould, with obvious advantages from an industrial point of view. Depending on the type of application it is possible to select the rubber of a suitable nature and the number of layers and/ or the characteristics of the glassfibre- based structures in order to obtain a given level of rigidity or flexibility.
Other modifications and/or variants of the present invention which are conceptually equivalent are possible and may be envisaged, without departing from the scope of the appended claims.
For example, in place of layers of cotton gauze, it is possible to use layers of other materials having a similar capability.

Claims

1. A ttay-shaped mould (10), of the type used for the manufacture of slabs of conglomerate material, characterized in that it comprises a composite material consisting of at least two layers of an elastomer material (Ia, Ib, Ic) and one glassfibre-based structure (2a, 2b) arranged in between and subjected to hot pressure vulcanization.
2. A tray-shaped mould (10) according to Claim 1, characterized in that said at least one glassfibre-based structure (2a, 2b) is in the form of a mat.
3. A tray-shaped mould (10) according to Claim 1, characterized in that said at least one glassfibre-based structure (2a, 2b) is in the form of a netting of the open- mesh type.
4. A tray-shaped mould (10) according to Claim 3, characterized in that the meshes of said netting are at least of a size 4 x 4 mm.
5. A tray-shaped mould (10) according to Claim 1, characterized in that it also comprises a cotton gauze (3) applied onto at least the outer surface of the bottom wall
(12) of the mould (10).
6. A tray-shaped mould (10) according to Claim 1, characterized in that said layers of elastomer material (Ia, Ib, Ic) are of an EPM or EPDM rubber.
7. A tray-shaped mould (10) according to Claim 1, characterized in that said layers of rubber (Ia, Ib, Ic) are three in number and said layers of glassfibre-based structure (2a, 2b) are two in number, each of the layers of glassfibre-based structure being arranged in between two layers of elastomer material.
8. A tray-shaped mould (10) according to Claim 1, characterized in that said layers of elastomer material (Ia, Ib, Ic) have a thickness of at least 1 mm.
9. A tray-shaped mould (10) to Claim 1, characterized in that said vulcanization is performed at the specific vulcanization temperature of the elastomer material fotroing said layers (Ia, Ib, Ic) and at a pressure of between 30 and 60 kg/cm2.
PCT/IT2004/000445 2004-08-05 2004-08-05 Tray-shaped mould made of a vulcanized composite material WO2006013589A1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
PCT/IT2004/000445 WO2006013589A1 (en) 2004-08-05 2004-08-05 Tray-shaped mould made of a vulcanized composite material

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
PCT/IT2004/000445 WO2006013589A1 (en) 2004-08-05 2004-08-05 Tray-shaped mould made of a vulcanized composite material

Publications (1)

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Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1944147A1 (en) * 2007-01-15 2008-07-16 Shell Internationale Researchmaatschappij B.V. Mould and process for shaping a sulphur cement product
EP1995030A3 (en) * 2007-03-30 2009-08-19 M.E.RIN S.r.l. Modular mould, in particular for artificial stone
EP2572847A1 (en) * 2011-09-22 2013-03-27 Shell Internationale Research Maatschappij B.V. Process for shaping a sulphur cement product
IT202000008953A1 (en) * 2020-04-24 2021-10-24 Dario Toncelli Forming tray for the production of agglomerated material plates, method of making such forming tray and method of production of agglomerated material plates
US11161277B2 (en) 2018-02-06 2021-11-02 Jeonjin Co., Ltd. Mold for manufacturing slab and manufacturing method thereof

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1382486A (en) * 1971-04-28 1975-02-05 Gen Electric Multilayer bonded structures
US3989790A (en) * 1974-03-22 1976-11-02 Sws Silicones Corporation Method for preparing silicone rubber molds
FR2657293A1 (en) * 1990-01-24 1991-07-26 Valeo Method of producing a material based on a reinforced elastomer, as well as a reinforced elastomer material especially obtained by this method
WO2001042007A1 (en) * 1999-12-06 2001-06-14 Luca Toncelli Fabric reinforced rubber for sheet for the production of slabs of resin hardend finely divided stone material

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1382486A (en) * 1971-04-28 1975-02-05 Gen Electric Multilayer bonded structures
US3989790A (en) * 1974-03-22 1976-11-02 Sws Silicones Corporation Method for preparing silicone rubber molds
FR2657293A1 (en) * 1990-01-24 1991-07-26 Valeo Method of producing a material based on a reinforced elastomer, as well as a reinforced elastomer material especially obtained by this method
WO2001042007A1 (en) * 1999-12-06 2001-06-14 Luca Toncelli Fabric reinforced rubber for sheet for the production of slabs of resin hardend finely divided stone material

Cited By (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1944147A1 (en) * 2007-01-15 2008-07-16 Shell Internationale Researchmaatschappij B.V. Mould and process for shaping a sulphur cement product
WO2008087124A1 (en) * 2007-01-15 2008-07-24 Shell Internationale Research Maatschappij B.V. Mould and process for shaping a sulphur cement product
EA016011B1 (en) * 2007-01-15 2012-01-30 Шелл Интернэшнл Рисерч Маатсхаппий Б.В. Process for shaping a sulphur cement product
US8252222B2 (en) 2007-01-15 2012-08-28 Shell Oil Company Mould and process for shaping a sulphur cement product
KR101460821B1 (en) * 2007-01-15 2014-12-02 쉘 인터내셔날 리써취 마트샤피지 비.브이. Mould and process for shaping a sulphur cement product
EP1995030A3 (en) * 2007-03-30 2009-08-19 M.E.RIN S.r.l. Modular mould, in particular for artificial stone
EP2572847A1 (en) * 2011-09-22 2013-03-27 Shell Internationale Research Maatschappij B.V. Process for shaping a sulphur cement product
US11161277B2 (en) 2018-02-06 2021-11-02 Jeonjin Co., Ltd. Mold for manufacturing slab and manufacturing method thereof
EP3521008B1 (en) 2018-02-06 2022-03-09 Jeonjin Co., Ltd. Mold for manufacturing slab and manufacturing method thereof
IT202000008953A1 (en) * 2020-04-24 2021-10-24 Dario Toncelli Forming tray for the production of agglomerated material plates, method of making such forming tray and method of production of agglomerated material plates
WO2021214644A1 (en) * 2020-04-24 2021-10-28 Dario Toncelli Moulding tray for manufacturing slabs made of agglomerate material, method for realizing such moulding tray and method for manufacturing slabs made of agglomerate material

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