WO2011025346A1

WO2011025346A1 - Mixture, stone laminate and board comprising particles of volcanic rock which can be used for construction and decoration, and corresponding production methods

Info

Publication number: WO2011025346A1
Application number: PCT/MX2009/000086
Authority: WO
Inventors: Jesús Federico ARROYO BERNAL
Original assignee: Arroyo Bernal Jesus Federico
Priority date: 2009-08-24
Filing date: 2009-08-24
Publication date: 2011-03-03
Also published as: MX2010012554A; MX355121B; MX359607B; MX2010012553A; WO2011025349A1

Abstract

The invention relates to a mixture that can be used to produce a stone laminate on a solid base, which can be used for decoration and comprises: particles of volcanic rock, a vinyl-acrylic copolymer, a polyvinyl acetate resin, styrene and butyl acrylate copolymers, magnesium hydrosilicate, and water. The invention also relates to a board that can be used for construction and the decoration of constructions, formed by a stone laminate made from the aforementioned mixture and a solid base. The invention further relates to a method for preparing said mixture and to a method for producing the board that can be used for construction and for the decoration of the surfaces of constructions.

Description

MIX, STONE AND PLATE SHEET, BASED ON VOLCANIC ROCK PARTICLES, USEFUL

IN CONSTRUCTION AND DECORATION; AND ITS ELABORATION PROCESSES

TECHNICAL FIELD OF THE INVENTION

The present invention relates to the technical field of construction, decoration, specifically in the finishes and decorations of constructions, since it provides a mixture, sheet of stone and plate, useful for the finishes and decorations of construction surfaces and other objects; as well as the methods for preparing them. Where such products are made of volcanic rock particles.

BACKGROUND OF THE INVENTION

Volcanic rocks have always been a highly valued material for their great beauty and ease of being carved and sculpted by man. What has caused it to be increasingly scarce and therefore more expensive to use in modern buildings, so they have become an elitist product that can only be used in luxury buildings.

The erosion of the soil in Mexico due to the exploitation of volcanic rocks in the quarries was 718 million tons, causing environmental pollution of more than 37 million tons of solid waste that was not used in the national territory (INEGI, system of economic and ecological accounts). 2004).

Several plates are known with an appearance that mimics the natural stone but they are still imitations, since when they are touched, smelled and seen closely, they are perceived as not stones. These plates are generally used in buildings made largely of prefabricated building materials as it facilitates installation costs and saves time.

In that category there are also plates of aluminum, polyethylene and other materials with a natural stone cover that was extracted in limited dimensions in relation to its weight and the size of the plate that supports it. These in turn were adhered to the plates by synthetic adhesives, so that the process of making these plates has very high costs and dimensions limited to the size of the rock from which it was extracted making the part and method of manufacture are limited in size and shape Natural volcanic rock plates exist for thousands of years and the biggest drawbacks are their weight, transport and placement. The plates extracted from natural volcanic rocks usually have some fragility when maneuvering, since vibrations or impacts on them can cause them to fragment. So they have to be done thick enough to have greater strength. At the time of installation in a wall, these usually have colossal weights that hinder or in some cases prevent being able to install them without suffering any damage. The wall on which they are installed must be of a resistant and firm enough material so that it can support the weight of the plate. Even so, there is always a risk that the constant impacts that occur at the time of fixation can fracture the plate.

Due to the aforementioned drawbacks, a mixture, stone sheet and plate was developed, based on volcanic rock particles, useful in decoration, and its manufacturing processes.

OBJECT OF THE INVENTION

An object of the present invention is a mixture for making a stone sheet on a solid base, useful for construction and decoration, which comprises particles of volcanic rock; a vinyl acrylic copolymer; a polyvinyl acetate resin; copolymers of butyl acrylate and styrene; Magnesium Hydrosilicate; and water.

Another object of this invention is a sheet of stone to decorate surfaces, obtained with the aforementioned mixture. A further object of the invention in question is a plate useful in construction and in the decoration of constructions, which comprises the aforementioned stone sheet and a solid base.

Another object of the present invention is a method for preparing the aforementioned mixture, which comprises: i) mixing the different particles that constitute the portion of volcanic rock particles, in a conventional manner; ii) moisten the portion of volcanic rock particles with 1 L of water for every 4 Kg of volcanic rock particles; iii) add, in its entirety, the vinyl acrylic copolymer; Ia polyvinyl acetate resin; the copolymers of butyl acrylate and styrene; and Magnesium Hydrosilicate; and iv) homogenize with a conventional stainless steel stirrer at 650 rpm for 75 minutes.

The invention also has as its object a method for preparing the aforementioned plate, which comprises: i) delimiting, on the solid base, the area where the stone sheet is placed, for this purpose a perimeter edge is provided on the solid base; ii) uniformly adding the mixture described in claims 1, 2, 3 and 4, over the area delimited in the previous stage, until the perimeter edge is covered; iii) let the mixture dry, outdoors, for 24 to 72 hours; iv) roughing the plate with diamond cups, according to the type of finish: rustic or smooth; v) cleaning the laminated plate of the originating residues, preferably, by means of a vacuum; vi) apply a layer of water-repellent sealant on the sheet; and vii) let the water-repellent sealer dry, outdoors, for 3 hours.

DETAILED DESCRIPTION OF THE INVENTION

The characteristic details of the mixture, stone sheet and plate, based on volcanic rock particles, useful in the construction, decoration, and its elaboration processes, of the present invention, are clearly shown in the following description and in the tables and accompanying figures.

Brief description of the figures:

Figure 1 is a graph showing the weights of the plate of the present invention, with respect to commercial products.

Figure 2 illustrates the behavior of thermal conductivity between the plate in question and some commercial products.

Figure 3 shows the resistance to hydrochloric acid of the plate of the present invention and some commercial products.

Figure 4 illustrates the installation time between the plate in question and other commercial products.

The idea arises because we know that volcanic rocks are of great beauty, high perceived value and that the deposits of these exist in limited places of the world, when these are exploited deposits generate a great waste that causes a strong pollution and environmental impact by not taking advantage of 100% volcanic rocks.

Upon detecting this problem, we realized that there was a great opportunity to create a product that would take advantage of the waste generated in the extraction of the large blocks of volcanic rock to create an artificial volcanic rock plate, but with the same characteristic of a natural volcanic rock plate, and thus converting these wastes into a volcanic rock plate that replaces 100% natural volcanic rock plates with the advantages of not creating pollution and being lighter in addition to the attributes described below .

Our goal was to obtain a product with the following characteristics:

• Have the same appearance, texture, color and aroma of natural volcanic rock plates or dimensional stones.

• Be at least 50% lighter than natural volcanic rock plates.

• Be resistant to acid rain (hydrochloric acid, sulfuric acid and nitric acid).

• Be resistant to ultraviolet rays.

• Be functional, easy and quick to place on any prefabricated or traditional element. Starting from the fact that it was better to use volcanic rock particles, preferably of waste, we performed tests to find the best combination of volcanic particles with binders. The copolymers used are commercial and that come in an emulsion presentation, as well as the resin. Water was also used to moisten the particles and complement the volume of the mixture, in a proportion of 1 L of water per 4 Kg of particles. The results are presented in Table 1.

Table 1. Behavior of different binders mixed with volcanic rock particles.

Plasticity was measured on a scale of 0 to 10, where the highest value indicates high plasticity.

As can be seen in said Table 1, the best combination was that of Copolymers of butyl acrylate and styrene + polyvinyl acetate resin + Vinyl-acrylic copolymer, because it presented greater plasticity, less drying time and no cracks. Although the drying time is accepted from 72 h, since no binders have a drying time of less than 72 h.

Once the best combination of binders was found, the best quantities or concentrations of each of the components were investigated. For this, an experiment was carried out, where we subjected each of the components to different amounts, until the most optimal doses were found. Table 2 shows these results.

To give this mixture a greater resistance to water, we decided to add Magnesium Hydrosilicate, thus creating a colloid mixture that is similar to volcanic lava, but cold, which has the property of adhering and melting on any material, which when dried has the same physical characteristics of a natural volcanic rock, so that they can be given the same finishes as natural dimensional stone plates. When analyzing the different doses of the components of the mixture in question, we observe that when we used 0.5% of all the copolymers, Magnesium Hydrosilicate and water, there was a significant number of particles that were distributed per cm2; the ranges being better than 1 to 10%, except in water, where the ideal range was 1 to 20%. When the copolymers and the Magnesium Hydrosilicate were applied beyond 15%, the appearance of the sheet was bad, since the excess causes the relief of the volcanic particles, so we decided not to use those doses, Although they had good hardness. Table 2. Behavior of the different doses to which the components of the mixture achieved were subjected.

PD = suspended particles. The appearance was rated based on a scale of 1 to 5, where the higher value means a better appearance. When working with resins, we found the copolymers that can be mixed with water and after many tests (see Table 3) we realized that the fine powder of the pulverized volcanic rock contains anorganic binders (inorganic functional mineral) that when mixed with water and copolymers based on butyl acrylate and styrene undergo a modification that allows them to have greater cohesion, adhesion and flexibility. With this mixture we could already laminate the base plates with natural volcanic rock but when drying, cracks were created in the laminate and we also found that this laminate had low resistance to friction and water, so we continued testing with different resins until we found an emulsion resin of polyvinyl acetate which, when added together with the copolymer Vinyl-acrylic emulsion, was able to improve the stability of our mixture thus improving its adhesion, its resistance to friction, water and cracks no longer appeared.

Table 3. Percentage of inorganic binders of the different volcanic rock particles.

As can be seen, in Table 3, the best combination of volcanic rock particles was 3 mm, 1 mm and 3 microns, so it was preferred to work with said combination; although also the combinations 2 mm + 1 mm + 2 microns and 1 mm + 5 microns + 1 mer, they also presented excellent results, so that said combinations are also considered in the present invention.

Having created the ideal mixture, we proceeded to laminate on a solid base with this mixture and after several tests we arrived at the following method: i) delimit, on the solid base, the area where the stone sheet is placed, for this purpose a perimeter edge on the solid base; ii) uniformly adding the mixture described in claims 1, 2, 3 and 4, over the area delimited in the previous stage, until the perimeter edge is covered; iii) let the mixture dry, outdoors, for 24 to 72 hours; iv) roughing the plate with diamond cups, according to the type of finish: rustic or smooth; v) cleaning the laminated plate of the originating residues, preferably, by means of a vacuum; vi) apply a layer of water-repellent sealant on the sheet; and vii) let the water-repellent sealer dry, outdoors, for 3 hours. The perimeter edge can be a rigid tape or strip, the height of which depends on the desired thickness of the stone sheet.

The way to prepare the mixture to prepare a stone sheet with the appearance of volcanic rock, comprises the following steps: i) mixing the different particles that constitute the portion of volcanic rock particles, in a conventional manner;

ii) moisten the portion of volcanic rock particles with 1 L of water for every 4 Kg of volcanic rock particles;

iii) add, in its entirety, the vinyl acrylic copolymer; Ia polyvinyl acetate resin; copolymers of butyl acrylate and styrene; and Magnesium Hydrosilicate; and iv) homogenize with a conventional stainless steel stirrer at 650 rpm for 75 minutes. What we get with this mixture is something similar to a cold volcanic lava that has the property of adhering and melting on any material, when dried it has the same hardness and physical characteristics of a natural volcanic rock, so it can be given same finished. It is important to mention that 90% of the formula is from natural products. Therefore, the invention also comprises a plate useful in the decoration of construction surfaces, as well as other objects, where said plate comprises the stone sheet originated with the mixture already described. The plates resulting from the process shown in this patent application are the solution to use the natural stone in modern architectural projects that, due to their dimensions, weight and structures, could never be coated with traditional plates of natural volcanic rock, since they have the weight limits and installation at a certain altitude. The intrinsic characteristics of this plate make it a product that has many applications in the construction and decoration industry. This plate has all the advantages of natural dimensional stones (never changes color, has the appearance, aroma and texture of natural rock) but without the disadvantage of weight since it is a much lighter product (up to 70% less weight) and can be used as a facade of buildings, shopping centers, schools, hospitals and houses. As a decorative element for interior and exterior walls, as a ceiling ceiling and can have so many uses where imagination is the only limit. The mixture used to laminate the plates allows us to apply the colloid mixture without using a mesh for adhesion and when drying, the rock melts on the material of the plate used creating a unique cohesion. Roughing with diamond cups gives an appearance equal to that of ornamental dimensional stones that are cut and polished with diamond discs.

The variety of laminates on the plates that can be obtained is equal to the variety of types and colors of the natural stones found in the different volcanic rock deposits in the world.

The benefits of this plate are shown below and with the figures included, you can verify such results, which have not been achieved by any of the conventional products: • Weight: 70% less than the natural volcanic rock.

• Appearance, texture, color and aroma of natural stone.

• Flexibility.

• Thermal isolation.

• Acid resistance. • Resistance to high temperatures.

• Resistance to water, to the action of bacteria, fungi and other organisms related to moisture.

• UV resistance (never changes color).

• Acoustic isolation.

• Easy and fast installation on any heavy or light material.

These plates laminated with volcanic rock can be used as a facade of buildings, shopping centers, schools, hospitals and houses. As a decorative element for interior and exterior walls, as a ceiling ceiling and can have so many uses where imagination is the only limit. And one of its great advantages is the ease of installation, since they can be installed indoors with the same ease and using the same conventional racks and screws used to install the plasterboard. For exteriors, they are installed with the same ease as cement plates and the same conventional racks and screws of cement plates are used. In the case of panels, they are installed with the same ease as the panels using the same conventional systems for placement.

These plates have the advantage of being fixed directly on the walls with thymes, adhesives or mortars without using racks.

These plates can also be used to build furniture and decorative items.

It should be noted that the mixture in question can be applied on surfaces of solid objects, to decorate them, such as containers, bottles, containers and any other solid surface, for which the surface of the object is simply cleaned, the mixture is applied by direct contact , it is allowed to dry, it is roughened, the dust is removed, the water-repellent sealant is added and the object is finished with its stone laminate.

Claims

1. A mixture to make a stone sheet on a solid base, useful for construction and decoration, characterized in that it comprises: particles of volcanic rock; a vinyl-acrylic copolymer; a polyvinyl acetate resin; copolymers of butyl acrylate and styrene; Magnesium Hydrosilicate; and water.

2. The mixture of claim 1, characterized in that the volcanic rock particles are in an amount of 65 to 80%; the vinyl acrylic copolymer between 1 to 10%; The polyvinyl acetate resin is from 1 to 10%; the copolymer of butyl acrylate and styrene in 1 to 10%; 1 to 10% Magnesium Hydrosilicate; and the water gives l to 20%.

3. The mixture of claims 1 and 2, characterized in that 50% of the volcanic rock particles have a diameter of 1 to 3 mm; 25% a diameter of 1 mm to 5 microns; and the other 25% a diameter of 1 to 3 microns.

4. The mixture of claim 3, characterized in that 50% of the volcanic rock particles have a diameter of 3 mm; 25% a diameter of 1 mm; and the other 25% a diameter of 3 microns.

5. The mixture of the preceding claims, characterized in that the vinyl-acrylic copolymer; Ia polyvinyl acetate resin; and copolymers of butyl acrylate and styrene are emulsified in a conventional manner.

6. A stone sheet, useful in the decoration of constructions and other objects, characterized in that it comprises the mixture of the preceding claims.

7. A plate useful for the construction and decoration of constructions, characterized in that it comprises: the stone sheet of claim 6; and a solid base.

8. The plate of claim 7, characterized in that the solid base is of a mineral material.

9. The plate of claim 8, characterized in that the mineral material is magnesium, plaster, cement, ceramic, aluminum, glass or the combination between them.

10. The plate of claim 7, characterized in that the solid base is of an organic material.

11. The plate of claim 10, characterized in that the organic material is wood, cardboard, polystyrene, polyethylene, polyurethane, PVC or the combination between them.

12. A method for preparing the mixture described in claims 1, 2, 3, 4 and 5, characterized in that it comprises the following steps: i) mixing the different particles that constitute the portion of volcanic rock particles, in a conventional manner;

ii) moisten the portion of volcanic rock particles with 1 L of water for each 4Kg of volcanic rock particles;

Ii) add, in its entirety, the vinyl acrylic copolymer; Ia polyvinyl acetate resin; copolymers of butyl acrylate and styrene; and Magnesium Hydrosilicate; and iv) homogenize with a conventional stainless steel stirrer at 650 rpm for 75 minutes.

13. The method of claim 12, characterized in that the vinyl-acrylic copolymer; Ia polyvinyl acetate resin; and copolymers of butyl acrylate and styrene are emulsified in a conventional manner.

14. A method for preparing the plate of claims 7, 8, 9, 10 and 11, characterized in that it comprises the following steps: i) delimiting, on the solid base, the area where the stone sheet of claim 5 is placed , for this, a perimeter edge is provided on the solid base;

ii) adding the mixture described in claims 1, 2, 3 and 4, over the area defined in

The previous stage, until the perimeter edge is covered;

iii) distribute, by means of vibration, the mixture over the entire destined area;

V) let the mixture dry, outdoors, for 24 to 72 hours;

v) roughing the plate with diamond cups, according to the type of finish: rustic or smooth; vi) cleaning the laminated plate of the originating residues, preferably, by means of a vacuum; vii) apply a layer of water-repellent sealant on the sheet; Y

viii) let the water-repellent sealer dry, outdoors, for 3 hours.

15. The method of claim 14, characterized in that the perimeter edge is a rigid tape or strip, the height of which depends on the desired thickness of the stone sheet.