WO2011119014A1

WO2011119014A1 - Method for producing slabs and blocks for decorating buildings

Info

Publication number: WO2011119014A1
Application number: PCT/MX2010/000025
Authority: WO
Inventors: Raúl ORTEGA SOTO
Original assignee: Ortega Soto Raul
Priority date: 2010-03-25
Filing date: 2010-03-25
Publication date: 2011-09-29

Abstract

The invention relates to the production of decorative slabs and blocks for buildings, ceilings and general handicraft, comprising concrete, plaster, resin, fiberglass or similar materials. The invention is characterized in that a heavy-duty, soft, plastic mould is formed using three classes of clay (Bentonite or Montmorillonite, Kaolinite and Illite), to which small amounts of a fourth class of clay known as Attapulgite can optionally be added. The mould is inlaid with any class of rock (mineralized, natural, artificial) and/or patterns using any kind of material and covered with an intermediate mesh in order to reinforce the slab and prevent contraction cracking. The castings of concrete, plaster, resin or similar materials are then poured. When completely dry, films of vinyl acrylic sealants are applied to provide protection from the elements.

Description

MANUFACTURING PROCESS OF Slabs and BLOCKS, FOR ORNAMENTATION

OF BUILDINGS

TECHNICAL FIELD The present invention relates to a technique, using clays as a molding system, in the manufacture of slabs and blocks, for the ornamentation of all kinds of buildings and crafts in general, based on concrete, plasters, resins, glass fibers or similar materials.

These products have their own and unparalleled characteristics, giving an especially attractive, original and elegant touch to any wall, wall or surface, with their inlays, of all kinds of rocks.

BACKGROUND OF THE INVENTION The manufacture of ornamental slabs for walls, ceilings or handicrafts in general, based on concrete, plasters, resins or similar materials, have not had transcendental changes over the years.

In general, its manufacture is based on a pattern, that is, since it is a mold with predetermined figures, its process is slow and expensive, for the following reasons: a) The equipment used by an Electrical Mechanic requires preventive maintenance and corrective, so it is reflected, in a high cost in labor and generating high costs of Electric Energy during its operation. b) In the market there are also slabs, blocks and handicrafts of natural rocks, elaborated in a semi-traditional way, frequently raising their costs in labor, supplies and fuels of all kinds, for being extracted from distant places; leaving our soils eroded, such is the case of quarries, marbles, blackboards, basalts, etc. c) The adhesion or fixation in the walls, with regard to the slabs, has not changed for years, since the use of the cements and traditional tile-adhesives persists. d) In the different systems of manufacture of ornamental slabs, or crafts based on concrete, plasters, resins, etc., I did not find that clays were used to achieve molding effects in any of its modalities, both in the decoration of walls, spaces, soffits or crafts. In a process of manufacturing blocks, based on concrete, using clays as molds, it is mentioned by Mr. Arthur M. Mickelson, in a patent application, filed at the United States Patent Office of North America, with July 15, 1913. Subsequently Mr. Mickelson, was granted US Patent Number 1, dated 169.985 I ^or February 1916.

In this patent letter, presented by Mr. Mickelson, he mentions a mold consisting of sediments and preferably clays, which when wetted, acquire the consistency of plasticity required,

In the aforementioned application, the classification or types of clays used are not specified, nor is it mentioned, the manufacture of ornamental slabs for buildings, soffits, handicrafts and the following concepts.

1. An intermediate mesh in the products.

2. Its fixing or adhesion to the walls with screws or anchors.

3. Clay molding system in handicrafts.

4. Protection with sealants, resin or silicone compounds.

DESCRIPTION OF THE INVENTION A more efficient alternative was sought in the manufacture and installation of ornamental slabs for walls, ceilings and all types of crafts based on concrete, plasters, resins or similar materials.

Currently, slabs composed of concrete, plaster or natural such as marbles, quarries, blackboards, basaltic rocks, their weight varies around 50 kilograms per square meter. This type of slabs, when they have been placed on surfaces and have to be removed for some reason, the walls are practically semi-destroyed, causing great economic losses in their rehabilitation.

It was also taken into account, that within its characteristics and originality, it exhibits in its decorative face a new aesthetic, new landscapes, consistency in its colors, resistant to abrasion and that in a harmonic way, they translate, convey feelings and astronomical observations.

This invention relates to a molding process, consisting of several kinds of clays, whose sole function is:

The shape of the decorative face of the slabs, blocks and crafts, resulting in an artificial product and as a base, concrete, resin plasters or similar materials, whose objective is to have products that meet the needs, tastes and preferences of the market, replacing all kinds of existing decorative slabs and blocks and largely avoiding the erosion of natural wealth, such as quarries, marbles, blackboards, basalts, etc.

The slabs and blocks, are works that have their own and unique characteristics, giving an especially attractive, original and elegant touch to any wall, wall or surface. Which, have a decorative face, with a variety of natural and / or artificial mineralized motifs and rocks

This novel molding process saves us:

Supplies and materials of the construction industry, such as arenas, gravels, cements, labor, electrical energy, fuels, transportation and inconvenience in placement, due to its low weight and ease of maneuverability, being its main characteristic, that of that is not required, sophisticated equipment for its elaboration.

Other innovative elements that characterize slabs and blocks are: Its light weight per square meter and that thanks to its production of molding and inputs of its components, we save approximately 66% of the weight, so that its fixation on surfaces in regard to slabs, is facilitated with screws or anchors, the cements or paste tiles, they remain an option and use in the placement of blocks. These slabs and their molding process used in their preparation, allow them to be characterized, being composed of at least three layers, these being:

The decorative layer, with all kinds of mineralized, non-metallic, precious, semi-precious, natural, artificial and / or all kinds of resin, clay, metallic, or any other type of material.

The second layer is a mesh, which can be metallic, of polymers, textiles, glass fibers or similar materials, in order to reinforce the slab, avoiding cracking by contraction and improving its structural integrity.

The third layer is the premixed concrete, plasters, resins, or other similar materials, which give it body and consistency.

The characteristic details of the slabs, their technique or molding process and their manufacturing system, are clearly shown in the following description and in the accompanying drawings, as well as in the illustration of those and following the same reference signs, for Indicate the parts and figures shown.

The three classes of clays of related lands are collected, these are pulverized, leaving the openings or gauge of their mesh, according to the type of slab, forming with each one, a mound to facilitate its maneuverability.

In a preferred embodiment, clays are used, with 20% Bentonite or Montmorilonite, 40% Kaolinite and 40% Hita.

To prepare the required mold, in which the slab is shaped, an amount of the 1st clay mound, known as Bentonite or Montmorilonite, is taken. Next, a quantity of clay known as Kaolinite is taken from the 2nd mound.

Finally, another quantity of clay known as Hita is taken from the third mound.

These amounts of clays must be proportional, which are mixed and water is added to form a soft, plastic and resistant paste, constituting the bed of clays that serve as a mold, whose sole function is to mold, the ornamental faces of the slabs, blocks, soffits and crafts.

There are other obvious possibilities, in the mixing of the quantities of clays, with which the same molding effect can be achieved. Even, the mixture in small quantities of a fourth class of clay known as Atapulguita.

Figure 1 is a perspective view of the structure of the frame 1, which can be metallic, wood or any other material and is formed of the following parts:

A base or flat floor, marked with 2.

The hinges are marked with 3.

The profiles of the frame being mobile are marked with 4.

Being the clays 5, in conditions of being molded, a portion is deposited, on the floor or base 2, of the frame 1, distributed manually or with a tool, until obtaining the desired roughness, texture or shape, whether natural or fruit of the human imagination

Also with the paste can be formed, irregular contour walls or profiles, which serve to contain the different layers of the slab or blocks, with motifs of known and artistic figures.

Then we proceed, to embed in the clay bed 5, I would suffer from rocks 6, natural, metallic, non-metallic, precious, semi-precious, artificial or mud motifs, metallic, resins, or any other kind of ' material, being formed a layer of rocky pavement 6, leaving an upper part of the set uncovered, with a certain separation, so that when the castings or premixes of concrete, gypsum, resins or similar materials are poured, they are adhered to these; thus providing a high degree of cohesion. When the inlays of the inputs remain in their corresponding places and on the clay layer they are covered with a mesh 7, which can be metallic, of polymers, textiles, natural fibers or any other material, in order to reinforce the slab, reducing cracking and improving its structural integrity. At this stage of the process, to give body and consistency to the slab, the layer of rocks 6, and mesh 7 would be covered, with the premixes of concrete 8, plasters, resins, or similar materials. To these, previously they were mixed, the preparation of the dyes, which already consist of a defined color, according to tastes and preferences. When the slab is set, it is released, opening out the profiles of the frame 4, the clays 5, which are still attached, are removed, being shaken or blown, recovering again for reuse.

Since the slab 9 is completely dry, either by natural means or by means of a controlled heat chamber, a sealant treatment or a silicone composition is applied to the decorative layer, to protect against weathering and proliferation of mushrooms.

If the dyes were not integrated to the pre-mixed previously, the next option is to apply the natural colors, and / or acrylics that are diluted with water. Being ecological, bright and that thanks to its formulation, they can decorate any space; its application can be by brush or spray equipment, allowing its remission of the layer of rock would suffer,

When the slab is decorated with their respective colors and so that they retain their attractiveness, originality and bright for a long time, they are applied a film of resins or varnishes, with brushes, or spray equipment.

According to the previous characterizations, the slabs 9, carry one or more perforations, which are determined by their dimensions, to be fixed with screws or anchors 10, in their respective studs, being installed on the surface 1 1, just by screwing it or Press it, there is also the option of being coupled with traditional cement or glue-tile adhesives.

The slabs 9 being installed, in a space or wall 1 1, the perforations, heads of the anchors or screws 10, are hidden with paint, plasters, resins or cements, forming part of the decoration.

The tip 12, or joint of the slabs, is sealed with silicones, plasters, cements, or with the traditional tiles, acquiring greater resistance to deformation and preventing the accumulation of dust or bugs in possible holes.

BRIEF DESCRIPTION OF THE FIGURES

Figure 1 is a perspective view of the frame 1 for slabs, showing the base 2, the hinges 3 and the profiles 4. The characteristics of the block frame are similar, except for their thickness.

Figure 2, is a sectioned perspective view that shows the different layers that form the slab such as:

The clay bed 5, the rock layer 6, the mesh 7 and the premixed layer of concrete, plasters, resins or similar materials 8.

Figure 3 is a cross section showing the installation of the slab 9, being fixed by anchors or screws 10, on a surface or wall 1 1.

Figure 4 shows a perspective view of the slabs 9, installed on a surface 1 1. This mural of slabs, is designed to perform unique shapes, in parks, residences, and attractive shopping centers, its prints cover the anchor heads and screws with which they were fixed. These tiles are joined by a tip 12, composed of silicones or traditional cements.

Claims

CLAIMS.

Having satisfactorily described my invention, I consider it as a novelty, therefore, the claim of my exclusive property, what is contained in the following Clauses:

1) Manufacturing process of slabs and blocks, for ornamentation of buildings, characterized in that it comprises the following steps: a) Three kinds of clays are assembled, preferably 20% of Bentonites or Montmorillonites, 40% of Kaolinites and 40% of Hitas.

b) They are sprayed independently, leaving their gauge or mesh opening according to the type of slab, forming three mounds, for easy handling.

c) The clays are mixed in similar quantities.

d) Water is added to the mixture, until it forms a soft, plastic and resistant paste, becoming the mold, whose only function is to mold the decorative face. e) Obtained the paste, a portion is deposited on the floor or base of a frame, distributed manually or with a tool, until obtaining the desired roughness, texture or shape, whether natural or fruit of the human imagination.

f) They are embedded in the mold, would suffer from mineralized, metallic, non-metallic, precious or semi-precious, artificial or resin, glass, mud, or any other kind of material.

g) An intermediate mesh is added to the surface of rocks or motifs, in order to reinforce the assembly and reduce cracking.

h) The premixes of concrete, plasters, resins or similar materials are poured to give it body and consistency; these castings, already have the dyes previously integrated.

i) When the slab has set, it is released from the frame, its drying is natural or by means of a controlled heat chamber.

j) If the dyes were not previously integrated into the premixes, the option is to apply them in the first layer of the slab, such as oil, natural and / or acrylic, which are diluted with water, these being ecological, bright and thank you to its formulation, They can decorate any space, their application can be by brush or spray equipment.

k) The slabs are characterized by being composed of three layers:

The first sporting all kinds of rocks, the second one a mesh and the third layer to give it body and consistency, the premixed concrete.

1) The blocks differ only by lacking mesh, compensated for their thickness.

2) Slab and block manufacturing process for building ornamentation.

They are characterized in that there are other obvious possibilities of mixing, of the percentages of the clays, with which the same molding effect can be achieved, including the mixing of a fourth class of clay known as Atapulguita.

3) Slab and block manufacturing process, for building ornamentation.

According to claim 1, characterized in that in step f, clays would be embedded in the surface or mattress of clays, it would suffer from all kinds of rocks, metallic motifs, mud, resins, wood or any other kind of material, leaving space in the upper part and an opening between the inputs so that when the castings or premixes of concrete, plasters, resins, or similar materials are poured, they adhere to these, all the components, with a high degree of cohesion.

4) Manufacturing process of slabs and blocks, for ornamentation of buildings.

According to claim 1, characterized in that in step g, the intermediate mesh can be metallic, of polymers, textiles, natural fibers or any other type of material, in order to reinforce it, reducing cracks and improving its structural integrity .

5) Slab and block manufacturing process, for building ornamentation.

At this stage of the process, the slabs and blocks are characterized, because when pouring the premixes of concrete, plasters, resins or similar materials, these were integrated into the dyes. 6) Manufacturing process of slabs and blocks, for ornamentation of buildings.

The production of slabs and blocks are characterized, because if the dyes were not previously integrated according to step j of claim 1, the option is to apply them in the first layer, with brushes or spray equipment.

7) Slab and block manufacturing process for building ornamentation.

According to claim 1, characterized in that when the slab has set, it is released from the frame, the adhered clays are removed, being shaken or blown, these are recovered for reuse,

8) Slab and block manufacturing process, for building ornamentation

According to claim 1, characterized in that:

When the slab is completely dry, either by natural means or by means of a controlled heat chamber, a sealant, vinyl-acrylic or silicone composition film is applied to protect it from weathering and fungal growth.

9) Manufacturing process of slabs and blocks, for ornamentation of buildings.

According to claims 5 and 6, characterized in that:

The slab according to the previous characterizations, carries one or more perforations, being determined by its dimensions, to be fixed with screws or expansion anchors, in their respective studs, just by pressing or screwing it, the blocks are placed and stuck in the traditional way.

10) Slab and block manufacturing process for building ornamentation.

According to claim 7, characterized in that:

The slabs when installed, the perforations and the heads of anchors or screws, are hidden with paints, plasters, rocks, cements or silicones.

1 1) Slab and block manufacturing process for building ornamentation.

According to claim 8, it is characterized in that: The joint of slabs or emboquillado, is sealed with silicones, cements or the traditional tile-tiles, increasing the resistance and avoiding movements, dust and bugs.

12) Manufacturing process of slabs and blocks, for ornamentation of buildings.

It is characterized in that: With the paste composed of clays, walls or profiles can be formed, with irregular contours, which serve to contain the different layers of the slab and / or blocks.