WO2017182849A1 - Textile decorated moisture resistant finish plate and method of producing thereof - Google Patents
Textile decorated moisture resistant finish plate and method of producing thereof Download PDFInfo
- Publication number
- WO2017182849A1 WO2017182849A1 PCT/IB2016/052301 IB2016052301W WO2017182849A1 WO 2017182849 A1 WO2017182849 A1 WO 2017182849A1 IB 2016052301 W IB2016052301 W IB 2016052301W WO 2017182849 A1 WO2017182849 A1 WO 2017182849A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- resin
- layer
- textile
- gel coating
- previous
- Prior art date
Links
- 239000004753 textile Substances 0.000 title claims abstract description 43
- 238000000034 method Methods 0.000 title claims abstract description 35
- 239000002131 composite material Substances 0.000 claims abstract description 48
- 238000005520 cutting process Methods 0.000 claims abstract description 12
- 238000010030 laminating Methods 0.000 claims abstract description 5
- 239000010410 layer Substances 0.000 claims description 80
- 239000011347 resin Substances 0.000 claims description 48
- 229920005989 resin Polymers 0.000 claims description 48
- 239000011248 coating agent Substances 0.000 claims description 39
- 238000000576 coating method Methods 0.000 claims description 39
- 230000002787 reinforcement Effects 0.000 claims description 14
- 239000004575 stone Substances 0.000 claims description 13
- 239000002966 varnish Substances 0.000 claims description 13
- 239000000203 mixture Substances 0.000 claims description 12
- 239000000835 fiber Substances 0.000 claims description 8
- 239000002184 metal Substances 0.000 claims description 8
- 229910052751 metal Inorganic materials 0.000 claims description 8
- 229920001225 polyester resin Polymers 0.000 claims description 8
- 239000004645 polyester resin Substances 0.000 claims description 8
- 238000010438 heat treatment Methods 0.000 claims description 7
- 238000005259 measurement Methods 0.000 claims description 7
- 239000004568 cement Substances 0.000 claims description 6
- 239000003822 epoxy resin Substances 0.000 claims description 5
- 229920000647 polyepoxide Polymers 0.000 claims description 5
- CSCPPACGZOOCGX-UHFFFAOYSA-N Acetone Chemical compound CC(C)=O CSCPPACGZOOCGX-UHFFFAOYSA-N 0.000 claims description 4
- 229920000178 Acrylic resin Polymers 0.000 claims description 4
- 239000004925 Acrylic resin Substances 0.000 claims description 4
- 238000005452 bending Methods 0.000 claims description 4
- 239000011247 coating layer Substances 0.000 claims description 4
- 230000007547 defect Effects 0.000 claims description 4
- 238000009499 grossing Methods 0.000 claims description 4
- 239000004579 marble Substances 0.000 claims description 4
- -1 polyethylene terephthalate Polymers 0.000 claims description 4
- 229920000139 polyethylene terephthalate Polymers 0.000 claims description 4
- 239000005020 polyethylene terephthalate Substances 0.000 claims description 4
- 239000003082 abrasive agent Substances 0.000 claims description 3
- 239000000975 dye Substances 0.000 claims description 3
- 239000000945 filler Substances 0.000 claims description 3
- 238000004519 manufacturing process Methods 0.000 claims description 3
- 239000004033 plastic Substances 0.000 claims description 3
- 229920003023 plastic Polymers 0.000 claims description 3
- 238000005507 spraying Methods 0.000 claims description 3
- NIXOWILDQLNWCW-UHFFFAOYSA-N acrylic acid group Chemical group C(C=C)(=O)O NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 claims description 2
- 150000001875 compounds Chemical class 0.000 claims description 2
- 229910003460 diamond Inorganic materials 0.000 claims description 2
- 239000010432 diamond Substances 0.000 claims description 2
- 238000004512 die casting Methods 0.000 claims description 2
- 238000010422 painting Methods 0.000 claims description 2
- 229920006267 polyester film Polymers 0.000 claims description 2
- 230000001681 protective effect Effects 0.000 claims description 2
- 239000005060 rubber Substances 0.000 claims description 2
- 239000007921 spray Substances 0.000 claims description 2
- 235000013311 vegetables Nutrition 0.000 claims description 2
- 239000000499 gel Substances 0.000 claims 1
- 238000003475 lamination Methods 0.000 claims 1
- 239000000463 material Substances 0.000 abstract description 6
- 238000010276 construction Methods 0.000 description 5
- 239000004744 fabric Substances 0.000 description 4
- 239000011241 protective layer Substances 0.000 description 3
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 2
- 239000004698 Polyethylene Substances 0.000 description 2
- 238000005516 engineering process Methods 0.000 description 2
- 239000003365 glass fiber Substances 0.000 description 2
- 239000010440 gypsum Substances 0.000 description 2
- 229910052602 gypsum Inorganic materials 0.000 description 2
- 238000005470 impregnation Methods 0.000 description 2
- 229910010272 inorganic material Inorganic materials 0.000 description 2
- 239000011147 inorganic material Substances 0.000 description 2
- 229920000573 polyethylene Polymers 0.000 description 2
- 238000007639 printing Methods 0.000 description 2
- 230000005855 radiation Effects 0.000 description 2
- 239000000126 substance Substances 0.000 description 2
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 2
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 1
- 238000005299 abrasion Methods 0.000 description 1
- 230000032683 aging Effects 0.000 description 1
- 230000004888 barrier function Effects 0.000 description 1
- 229910052799 carbon Inorganic materials 0.000 description 1
- 239000000919 ceramic Substances 0.000 description 1
- 229910052729 chemical element Inorganic materials 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 239000003086 colorant Substances 0.000 description 1
- LNEPOXFFQSENCJ-UHFFFAOYSA-N haloperidol Chemical compound C1CC(O)(C=2C=CC(Cl)=CC=2)CCN1CCCC(=O)C1=CC=C(F)C=C1 LNEPOXFFQSENCJ-UHFFFAOYSA-N 0.000 description 1
- 229910052742 iron Inorganic materials 0.000 description 1
- 239000007769 metal material Substances 0.000 description 1
- 230000000485 pigmenting effect Effects 0.000 description 1
- 238000005498 polishing Methods 0.000 description 1
- 229920000728 polyester Polymers 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 238000010186 staining Methods 0.000 description 1
- 210000002268 wool Anatomy 0.000 description 1
Classifications
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- E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
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- B28B19/0015—Machines or methods for applying the material to surfaces to form a permanent layer thereon on multilayered articles
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- B29C67/24—Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00 characterised by the choice of material
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- 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
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- B32B2307/00—Properties of the layers or laminate
- B32B2307/70—Other properties
- B32B2307/732—Dimensional properties
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2419/00—Buildings or parts thereof
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2451/00—Decorative or ornamental articles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2607/00—Walls, panels
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2002/005—Appearance of panels
Definitions
- the invention relates to the field of finish plates and methods of producing thereof.
- the invention is a textile-decorated moisture -resistant finish plate and a method of producing thereof.
- the finish plate of the invention is used as a floor or a wall plate in interior and exterior design.
- Patent application No. JPH0525291 discloses a method for attaching carbon fibre material to a hydraulic inorganic material to make fibre-reinforced hydraulic inorganic material. This solution is used in automobile and aviation industries and is not a suitable material for interior or exterior finish in construction.
- Patent application No. CA1141640 discloses a plate component for use in construction, where a gypsum panel is reinforced with fabric or a web and glass fibres, whereas the gypsum is faced with fabric.
- Patent application No. DEI 02007012651 discloses a fabric that is applied to a composite material, whereas a pattern is printed or painted straight onto it.
- Composite materials are used in construction and as a protective layer.
- a drawback of the solutions known in prior art is faster ageing in moist conditions and under sunlight; in addition, the sizes and the selection of designs are limited.
- the present invention describes a textile-decorated moisture-resistant finish plate and a method of producing thereof.
- the finish plate consists of a rigid composite layer with a gel coat; on top of it, there is a decorative surface, which is a textile impregnated with resin to make it moisture-resistant; the rigid composite layer with a gel coating consists of stone rubble glued to the gel coating with resin and a reinforced cement mix layer poured onto the rubble.
- the method of producing a finish plate begins with creating a mould, followed by making the composite layer with a gel coating and a decorative surface, and lastly, laminating and cutting.
- Textile-decorated moisture-resistant finish plate is a rigid plate with a decorative textile surface, which allows selecting a requested pattern for a decorative surface.
- Textile decorated moisture resistant finish plate is used as a covering material for walls and floors indoors and outdoors.
- the advantages of this invention include a wider selection of decorative surfaces and measurements equalling the height of a room. Due to its greater bending strength, the decorated moisture resistant finish plates can be installed more readily; in addition, one of the embodiments of the invention offers finish plates with bent edges that will not leave joints in the corners.
- Textile decorated moisture resistant finish plates are also used as windowsills, decorative coverings for furniture, such as a table covering placed on the upper surface of a table, or as a covering for any other interior design element; in addition, these offer a possibility of producing various interior design elements.
- FIG 1 cross-section of the finish plate from the side.
- Textile decorated moisture resistant finish plate consists of a rigid composite layer with a gel coating (1) and a decorative surface (2).
- Decorative surface (2) is a textile (3) impregnated with a resin to make it moisture resistant
- the rigid composite layer (1) with a gel coating consists of stone rubble (4) glued to the gel coating with resin and of a layer of cement mixture, containing reinforcement (5), which is poured on the rubble as depicted on FIG 1.
- the decorative surface (2) of the finish plate is covered with a UV-radiation resistant varnish.
- the composite layer (1) is covered with a protective resin coat, which is white or any other colour and prevents water staining of the decorative surface (2).
- Producing a textile decorated moisture resistant finish plate consists of the following stages: pouring a mould, making a composite layer (2) with a gel coating and a decorative surface (2), laminating and cutting.
- a plate and sideboards made from timber, metal, plastic or rubber are used.
- a particleboard plate is used as a bottom of the mould, and in one embodiment of the invention, the surface of the mould is sculptured or roughened in the case of a metal or timber plate, improving the adherence of the next layer.
- a metal plate is used as a bottom of the mould. Timber or metal sideboards are attached around the plate, keeping the mixture on the plate and preventing it from spilling over the surface of the mould.
- the sideboards are in 100 mm increments in their length and sides, which enable using a large selection of sideboards; for example, in order to produce an interior finish plate with measurements of 3000 x 250 mm, sideboards in measurements 3100 x 350 mm are used. Sideboards are made based on the requested measurements of the finish plate. According to a preferred embodiment of the invention, sideboards have four sides, welded to each other to enable attaching these to the bottom of the mould all at once and to removing those all at once. An advantage of metal materials is that these are easier to clean and metal sideboards do not buckle. According to a preferred embodiment of the invention, the mould has a metal plate and metal sideboards, which are rigidly connected with a weld. According to an embodiment of the invention, heating elements are placed inside the mould.
- sideboards are not used; instead, the mould is made non-planar, where the lower plane is for making the cement mix layer and the upper plane functions as a barrier, whereas the mould is an integral whole without sideboards.
- the composite layer (1) provides the thickness and rigidity of the plate, and plates in various degrees of thickness can be produced depending on the amount of the composite.
- the composite layer (1) consists of self- smoothing floor levelling compound, stone rubble (4), fibre reinforcement (5) and a coating, which can be a gel coating, acrylic or polyester resin coating (6).
- the purpose of the stone rubble (4) is to improve adherence properties of the composite layer and gel coating, and fibre reinforcement provides the bending strength to the plate.
- marble rubble is used; however, in an alternative embodiment of the invention, other abrasive materials are used with a grain size of preferably ⁇ 1 mm and more preferably -0.5 mm.
- Gel coating consisting of polyester or epoxy resins based on other resins, is poured first into the prepared mould to produce a composite layer (1) with a gel coating.
- the gel coating is used to create an approximately 1 mm layer of colour on the composite layer to avoid water stains showing on the decorative surface, because the added composite has a dark colour, and when that composite gets wet, it becomes even darker.
- the gel coating is impregnated with a resin, and as a result, the colour of the gel coating will glimmer through the textile, which is placed onto the composite layer and gel coat.
- the gel coating is pigmented white; however, in alternative embodiments, the gel coating is pigmented with other colours, such as brown, yellow, red, blue or any other colour. Pigmenting the gel coating allows the preferred colour to glimmer through the decorative surface.
- Gel coating is applied to the surface of the mould in one or two layers by a spray method. After the gel coating layer is applied, a layer of polyester resin (6) is sprayed on top of it, followed by rubble (4) that is sprinkled on it, which is preferably marble rubble. Stone rubble (4) will remain inside the composite layer (1).
- the gel coating layer is monitored because it should not become hardened; instead, the application of both layers - the gel coating and polyester resin (6) - is done using wet-on-wet method to guarantee good adherence.
- a cement mixture is prepared according to the instructions of the manufacturer and poured into the mould onto the gel coat, which is covered with the polyester resin (6) and rubble (4); then, reinforcement (5), which is a fibre reinforcement web, is inserted into the mixture.
- the fibre reinforcement web consists of fine glass fibres, whereas the fibres form a web with openings of at least 1 mm.
- iron reinforcement is used instead of a fibre reinforcement web, thus guaranteeing a better bending strength in load-bearing constructions.
- the mixture poured into the mould is self- smoothing and spreads between the stone rubble (4).
- the mould contains a vibration system, which shakes the mould so the composite spreads better. After the mixture hardens, sideboards and the composite layer (1) are removed from the mould, and the components of the mould are cleaned.
- the defects are corrected by spraying a new gel coating layer.
- the gel coating is softened by placing heating mats on the gel coat; under those, the gel coating softens, thereby ensuring better adherence to the next layer. If there are no defects, gel coating is polished to ensure adherence, upon the impregnation of the textile, between the decorative layer that is added next and the gel coat.
- Decorative surface (2) consists of textile (3) that has been made moisture-resistant by impregnating it with acrylic resin, whereas the textile (3) has been decorated beforehand by using silk painting, dying textiles with vegetable dyes, batik or other methods.
- the textile (3) is stretched onto the composite layer (1), followed by the layer going through a printing process, which produces a decorated surface with a composite layer (1) in the desired design.
- textile (3) will be printed without the composite layer (1), whereas the textile (3) is stretched on a frame or other object. Dying is also conducted on a stretched textile (3).
- Fillers are added to the resin that is used for impregnating the textile by the method of dispensing, thus improving the fire resistance of the resins and guaranteeing fire resistance, for example, in exterior wall panels.
- other chemical elements are added to the resins that cause reactions and enable creating various decorative surfaces.
- the chosen textile (3) is impregnated with a resin, providing the textile (3) with moisture resistance and a protective layer.
- the impregnated decorative surface (2) is placed on the composite layer (1) and stretched onto it by using a staple gun.
- the decorative surface (2) is hand-laminated.
- the first layer or resin is applied to the textile (3), thus impregnating the textile with resin and achieving adherence with a composite layer (1).
- air bubbles are laminated out of the surface.
- a film which is a polyethylene film, and in preferred embodiments, a polyester film or a polyethylene terephthalate (PET) resin film.
- PET polyethylene terephthalate
- the film is planar, or alternatively, various patterns are pressed into the film. Patterns or shapes are created into the film, which are copied on the decorative surface (2), where resin impregnates all spaces under the film, and when the film is removed, the pattern which is pressed into the film or made using any other method can be seen on the decorative surface. Film is used for obtaining a smooth surface and hardening the resin.
- die casting method is used for producing the decorative surface (2); in this case, a film is placed on the textile (3) after the textile (3) is stretched onto the composite layer (1), and the textile (3) between the composite layer and film, as well as air layer therein, are sealed to be air-tight; then, air is removed with a vacuum pump; after air is removed, a pump is used to press resin into the space, the textile (3) is impregnated with resin, and film is removed after hardening. After impregnation with a resin, the textile (3) is covered with a layer of varnish, thus providing a protective layer against UV radiation and chemicals.
- Decorative surface (2) is planar, or in alternative variants of the invention, non-planar, such as wavy or cracked.
- wool felt is used instead of textile (3).
- An angle grinder with a diamond blade and a stationary pitsaw, power grinder with a control bus or abrasive waterjet cutting are used for cutting the finish plate.
- the advantage of abrasive waterjet cutting when compared to stationary pitsaw is a streamlined cut. In both cases, large finish plates are prepared in moulds, whereas the plates could be as high as a room, or 2400 x 1200 mm, for example; by using the selected cutting technology, the produced finish plates are cut into smaller finish plates if necessary.
- the cut edge is heated with a convector, for example, to heat the plastic decorative surface so it becomes soft.
- a convector for example, to heat the plastic decorative surface so it becomes soft.
- This method guarantees an edge that can be cut perfectly, that has no tears from the blade and the edge does not become substandard.
- the edge that is being cut softens and will remain smooth.
- the finish plate is cut immediately after the film is removed and before the resin hardens. When the film is removed, the resin/decorative surface (2) is soft, and when cutting it immediately, it does not tear pieces out of the edge.
- the cut edge of the finish plate has a 90-degree angle and is sharp; therefore, the edges are rounded by smoothing or polishing.
- Interior finish plates with a bent surface are produced by taking advantage of the plasticity of the resin. For this purpose, the measurements of the requested bend of the finish plate are marked on the area that needs to be bent. After this, a cut is made into the composite layer to the depth of the reinforcement (5).
- the area to be bent is heated for about 20 seconds with a convector; after heating it, one side of the plate is bent with a smooth and slow motion to the desired angle, and the plate is fixed for about 20 seconds until the epoxy resin hardens again. After this, the interior finish plate is placed to the desired spot on the base surface.
- a plate with bent edges is produced during the production of the composite layer (1) where the bent areas are prepared in the mould.
- a 3-dimensional (3D) appearance is given to the decorative surface of the plates, using the properties of resins for this purpose.
- a 3D appearnce could be a decorative surface that depicts sea waves or a decorative surface that resembles any other protruding shape.
- Inner and outer corner solutions are applied to the plate on-site during the construction after the plates have been distributed by a plater. It is recommended that these plates are installed after whole plates are installed, or as a last stage before jointing.
- the finish plates can be used to make an entire bathroom according to provided measurements in a factory, which is assembled on-site after it is delivered. Finish plates are also used as modules for showers and baths, whereas module bathrooms are produced with floor and wall finish plates.
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Abstract
The invention is a textile-decorated moisture-resistant finish plate and a method of producing thereof. The finish plate is a rigid plate with a decorative textile surface that allows selecting any desired pattern for the decorative surface. The method of producing the finish plate consists of the following stages: preparing a mould, preparing the composite layer and decorative surface, laminating and cutting. Textile-decorated moisture-resistant finish plate is used as a covering material for walls and floors indoors and outdoors.
Description
Textile decorated moisture resistant finish plate and method of producing thereof Field of Technology
The invention relates to the field of finish plates and methods of producing thereof. The invention is a textile-decorated moisture -resistant finish plate and a method of producing thereof. The finish plate of the invention is used as a floor or a wall plate in interior and exterior design.
Background of the invention
Best-known similar solutions from the prior art are ceramic interior finish plates; however, their size, shape and design is limited. Prior art also has several solutions that use fabric for making reinforced materials or decorated surface finishes.
Patent application No. JPH0525291 discloses a method for attaching carbon fibre material to a hydraulic inorganic material to make fibre-reinforced hydraulic inorganic material. This solution is used in automobile and aviation industries and is not a suitable material for interior or exterior finish in construction.
Patent application No. CA1141640 discloses a plate component for use in construction, where a gypsum panel is reinforced with fabric or a web and glass fibres, whereas the gypsum is faced with fabric.
Patent application No. DEI 02007012651 discloses a fabric that is applied to a composite material, whereas a pattern is printed or painted straight onto it. Composite materials are used in construction and as a protective layer.
A drawback of the solutions known in prior art is faster ageing in moist conditions and under sunlight; in addition, the sizes and the selection of designs are limited.
Summary of the invention
The present invention describes a textile-decorated moisture-resistant finish plate and a method of producing thereof. The finish plate consists of a rigid composite layer with a
gel coat; on top of it, there is a decorative surface, which is a textile impregnated with resin to make it moisture-resistant; the rigid composite layer with a gel coating consists of stone rubble glued to the gel coating with resin and a reinforced cement mix layer poured onto the rubble. The method of producing a finish plate begins with creating a mould, followed by making the composite layer with a gel coating and a decorative surface, and lastly, laminating and cutting. Textile-decorated moisture-resistant finish plate is a rigid plate with a decorative textile surface, which allows selecting a requested pattern for a decorative surface.
Textile decorated moisture resistant finish plate is used as a covering material for walls and floors indoors and outdoors. The advantages of this invention include a wider selection of decorative surfaces and measurements equalling the height of a room. Due to its greater bending strength, the decorated moisture resistant finish plates can be installed more readily; in addition, one of the embodiments of the invention offers finish plates with bent edges that will not leave joints in the corners.
Textile decorated moisture resistant finish plates are also used as windowsills, decorative coverings for furniture, such as a table covering placed on the upper surface of a table, or as a covering for any other interior design element; in addition, these offer a possibility of producing various interior design elements.
List of figures
The preferred embodiments of the invention are described by referring to the attached figures, which depict the following:
FIG 1: cross-section of the finish plate from the side. Detailed description of the invention
Textile decorated moisture resistant finish plate consists of a rigid composite layer with a gel coating (1) and a decorative surface (2). Decorative surface (2) is a textile (3) impregnated with a resin to make it moisture resistant, whereas the rigid composite layer (1) with a gel coating consists of stone rubble (4) glued to the gel coating with resin and of a layer of cement mixture, containing reinforcement (5), which is poured on the
rubble as depicted on FIG 1. The decorative surface (2) of the finish plate is covered with a UV-radiation resistant varnish. The composite layer (1) is covered with a protective resin coat, which is white or any other colour and prevents water staining of the decorative surface (2).
Producing a textile decorated moisture resistant finish plate consists of the following stages: pouring a mould, making a composite layer (2) with a gel coating and a decorative surface (2), laminating and cutting.
For making a mould, a plate and sideboards made from timber, metal, plastic or rubber are used. According to one embodiment of the invention, a particleboard plate is used as a bottom of the mould, and in one embodiment of the invention, the surface of the mould is sculptured or roughened in the case of a metal or timber plate, improving the adherence of the next layer. In a more preferred embodiment of the invention, a metal plate is used as a bottom of the mould. Timber or metal sideboards are attached around the plate, keeping the mixture on the plate and preventing it from spilling over the surface of the mould. The sideboards are in 100 mm increments in their length and sides, which enable using a large selection of sideboards; for example, in order to produce an interior finish plate with measurements of 3000 x 250 mm, sideboards in measurements 3100 x 350 mm are used. Sideboards are made based on the requested measurements of the finish plate. According to a preferred embodiment of the invention, sideboards have four sides, welded to each other to enable attaching these to the bottom of the mould all at once and to removing those all at once. An advantage of metal materials is that these are easier to clean and metal sideboards do not buckle. According to a preferred embodiment of the invention, the mould has a metal plate and metal sideboards, which are rigidly connected with a weld. According to an embodiment of the invention, heating elements are placed inside the mould.
In making an alternative mould, sideboards are not used; instead, the mould is made non-planar, where the lower plane is for making the cement mix layer and the upper plane functions as a barrier, whereas the mould is an integral whole without sideboards.
After the sideboards are attached, the upper surface of the mould plate is processed with mould wax to prevent the composite layer (1) with a gel coating from sticking to the mould and to facilitate removal.
The composite layer (1) provides the thickness and rigidity of the plate, and plates in various degrees of thickness can be produced depending on the amount of the composite. The composite layer (1) consists of self- smoothing floor levelling compound, stone rubble (4), fibre reinforcement (5) and a coating, which can be a gel coating, acrylic or polyester resin coating (6). The purpose of the stone rubble (4) is to improve adherence properties of the composite layer and gel coating, and fibre reinforcement provides the bending strength to the plate. In a more preferred embodiment, marble rubble is used; however, in an alternative embodiment of the invention, other abrasive materials are used with a grain size of preferably ~1 mm and more preferably -0.5 mm.
Gel coating, consisting of polyester or epoxy resins based on other resins, is poured first into the prepared mould to produce a composite layer (1) with a gel coating. The gel coating is used to create an approximately 1 mm layer of colour on the composite layer to avoid water stains showing on the decorative surface, because the added composite has a dark colour, and when that composite gets wet, it becomes even darker. The gel coating is impregnated with a resin, and as a result, the colour of the gel coating will glimmer through the textile, which is placed onto the composite layer and gel coat. According to a preferred embodiment of the invention, the gel coating is pigmented white; however, in alternative embodiments, the gel coating is pigmented with other colours, such as brown, yellow, red, blue or any other colour. Pigmenting the gel coating allows the preferred colour to glimmer through the decorative surface.
Gel coating is applied to the surface of the mould in one or two layers by a spray method. After the gel coating layer is applied, a layer of polyester resin (6) is sprayed on top of it, followed by rubble (4) that is sprinkled on it, which is preferably marble rubble. Stone rubble (4) will remain inside the composite layer (1). When applying a polyester layer (6), the gel coating layer is monitored because it should not become hardened; instead, the application of both layers - the gel coating and polyester resin (6) - is done using wet-on-wet method to guarantee good adherence. Once the polyester resin layer (6) with stone rubble (4) has hardened, a cement mixture is prepared according to the instructions of the manufacturer and poured into the mould onto the gel coat, which is covered with the polyester resin (6) and rubble (4); then, reinforcement (5), which is a fibre reinforcement web, is inserted into the mixture. The fibre reinforcement web consists of fine glass fibres, whereas the fibres form a web with
openings of at least 1 mm. According to an alternative embodiment of the invention, iron reinforcement is used instead of a fibre reinforcement web, thus guaranteeing a better bending strength in load-bearing constructions. The mixture poured into the mould is self- smoothing and spreads between the stone rubble (4). In an alternative embodiment of the invention, the mould contains a vibration system, which shakes the mould so the composite spreads better. After the mixture hardens, sideboards and the composite layer (1) are removed from the mould, and the components of the mould are cleaned.
If defects are discovered on the surface of the gel coating when the composite layer (1) is removed from the mould, the defects are corrected by spraying a new gel coating layer. In an alternative embodiment of the invention, the gel coating is softened by placing heating mats on the gel coat; under those, the gel coating softens, thereby ensuring better adherence to the next layer. If there are no defects, gel coating is polished to ensure adherence, upon the impregnation of the textile, between the decorative layer that is added next and the gel coat.
Decorative surface (2) consists of textile (3) that has been made moisture-resistant by impregnating it with acrylic resin, whereas the textile (3) has been decorated beforehand by using silk painting, dying textiles with vegetable dyes, batik or other methods. When printing on the textile (3), the textile (3) is stretched onto the composite layer (1), followed by the layer going through a printing process, which produces a decorated surface with a composite layer (1) in the desired design. Alternatively, textile (3) will be printed without the composite layer (1), whereas the textile (3) is stretched on a frame or other object. Dying is also conducted on a stretched textile (3).
Fillers are added to the resin that is used for impregnating the textile by the method of dispensing, thus improving the fire resistance of the resins and guaranteeing fire resistance, for example, in exterior wall panels. In addition, other chemical elements are added to the resins that cause reactions and enable creating various decorative surfaces.
In order to make a decorative surface (2), the chosen textile (3) is impregnated with a resin, providing the textile (3) with moisture resistance and a protective layer. The impregnated decorative surface (2) is placed on the composite layer (1) and stretched onto it by using a staple gun.
The decorative surface (2) is hand-laminated. After the textile (3) is stretched onto a composite layer (1), the first layer or resin is applied to the textile (3), thus impregnating the textile with resin and achieving adherence with a composite layer (1). As the first layer of resin is applied, air bubbles are laminated out of the surface. After the first layer hardens, second layer is applied; on the second layer, a film is placed, which is a polyethylene film, and in preferred embodiments, a polyester film or a polyethylene terephthalate (PET) resin film. The film is planar, or alternatively, various patterns are pressed into the film. Patterns or shapes are created into the film, which are copied on the decorative surface (2), where resin impregnates all spaces under the film, and when the film is removed, the pattern which is pressed into the film or made using any other method can be seen on the decorative surface. Film is used for obtaining a smooth surface and hardening the resin. When hand-laminating, resin is spread onto the textile underneath the film, and after the resin hardens, the film is removed, leaving a smooth and even resin surface as a final result. In order to make resin harden faster on the surface of the textile (3), heat-radiating devices are used, such as floor heating mats or heat radiation lamps and convectors placed on the resin layer, so the heat from the devices hardens the resin faster.
In an alternative embodiment, die casting method is used for producing the decorative surface (2); in this case, a film is placed on the textile (3) after the textile (3) is stretched onto the composite layer (1), and the textile (3) between the composite layer and film, as well as air layer therein, are sealed to be air-tight; then, air is removed with a vacuum pump; after air is removed, a pump is used to press resin into the space, the textile (3) is impregnated with resin, and film is removed after hardening. After impregnation with a resin, the textile (3) is covered with a layer of varnish, thus providing a protective layer against UV radiation and chemicals.
After polyethylene film is removed from the layer of resin, two coats for varnish are sprayed onto the decorative surface (2), whereas the first is a primer coat that consists of a mixture of acetone and varnish, and the second is a 100% varnish layer. After the varnish sets, the decorative surface (2) is polished to achieve a glassy surface. The layer of varnish protects the finish plate from weather and chemicals, as well as ensures a more solid, hard, and abrasion-resistant surface. In an alternative embodiment of the invention, an filler is added to the varnish, such as a special grainy material, which
makes the surface of the varnish rougher and reduces smoothness. Decorative surface (2) is planar, or in alternative variants of the invention, non-planar, such as wavy or cracked. In an alternative variant of the invention, wool felt is used instead of textile (3).
An angle grinder with a diamond blade and a stationary pitsaw, power grinder with a control bus or abrasive waterjet cutting are used for cutting the finish plate. The advantage of abrasive waterjet cutting when compared to stationary pitsaw is a streamlined cut. In both cases, large finish plates are prepared in moulds, whereas the plates could be as high as a room, or 2400 x 1200 mm, for example; by using the selected cutting technology, the produced finish plates are cut into smaller finish plates if necessary.
While cutting, the cut edge is heated with a convector, for example, to heat the plastic decorative surface so it becomes soft. This method guarantees an edge that can be cut perfectly, that has no tears from the blade and the edge does not become substandard. When heating, the edge that is being cut softens and will remain smooth. In an alternative embodiment, the finish plate is cut immediately after the film is removed and before the resin hardens. When the film is removed, the resin/decorative surface (2) is soft, and when cutting it immediately, it does not tear pieces out of the edge. The cut edge of the finish plate has a 90-degree angle and is sharp; therefore, the edges are rounded by smoothing or polishing.
Interior finish plates with a bent surface are produced by taking advantage of the plasticity of the resin. For this purpose, the measurements of the requested bend of the finish plate are marked on the area that needs to be bent. After this, a cut is made into the composite layer to the depth of the reinforcement (5). In order to make the epoxy resin malleable, the area to be bent is heated for about 20 seconds with a convector; after heating it, one side of the plate is bent with a smooth and slow motion to the desired angle, and the plate is fixed for about 20 seconds until the epoxy resin hardens again. After this, the interior finish plate is placed to the desired spot on the base surface. According to an alternative method of the invention, a plate with bent edges is produced during the production of the composite layer (1) where the bent areas are prepared in the mould.
A 3-dimensional (3D) appearance is given to the decorative surface of the plates, using the properties of resins for this purpose. A 3D appearnce could be a decorative surface that depicts sea waves or a decorative surface that resembles any other protruding shape.
Inner and outer corner solutions are applied to the plate on-site during the construction after the plates have been distributed by a plater. It is recommended that these plates are installed after whole plates are installed, or as a last stage before jointing. In addition, the finish plates can be used to make an entire bathroom according to provided measurements in a factory, which is assembled on-site after it is delivered. Finish plates are also used as modules for showers and baths, whereas module bathrooms are produced with floor and wall finish plates.
Claims
1. Textile-decorated moisture-resistant finish plate, characterized in that the finish plate includes a rigid composite layer (1) with a gel coating and a decorative surface (2), wherein the decorative surface (2) is a textile (3) that is impregnated with resin to make it moisture-resistant, and the rigid composite layer (1) with a gel coating consists of stone rubble (4) that is glued to the gel coating with resin, as well as a layer of cement mixture that is poured onto the rubble and contains reinforcement (5).
2. Finish plate according to claim 1, characterized in that the textile (3) is decorated by using silk painting, dying the textile with vegetable dyes or batik.
3. Finish plate according to claims 1 and 2, characterized in that the decorative surface (2) is covered with UV-radiation resistant varnish and/or covered with a white or any other colour protective resin layer.
4. Finish plate according to any of the previous claims, characterized in that the composite layer (1) consists of self-smoothing floor levelling compound, stone rubble (4), fibre reinforcement (5), and gel, acrylic or polyester resin coat (6).
5. Finish plate according to claims 1 and 4, characterized in that the stone rubble (4) is marble rubble or any other abrasive material with a grain size of ~1 mm.
6. Finish plate according to any of the previous claims, characterized in that the gel coating comprises a polyester or epoxy resin that is based on other resins.
7. Finish plate according to claim 6, characterized in that the gel coating has thickness of ~1 mm.
8. Finish plate according to any of the previous claims, characterized in that the gel coating is pigmented white, brown, yellow, red or blue.
9. Finish plate according to any of the previous claims, characterized in that the decorative surface (2) has a three-dimensional appearance.
10. Method for producing a textile-decorated moisture-resistant finish plate, characterized in that the production process consists of the following stages: preparing a mould, making the composite layer (1) with a gel coating and the decorative surface (2), laminating and cutting.
11. Method according to claim 10, characterized in that the mould is made of timber, metal, plastic or rubber plate and sideboards, whereas the sideboards are attached around the plate and the upper surface of the mould is processed with a mould wax.
12. Method according to claim 12, characterized in that heating elements and/or a vibration system is installed in the mould.
13. Method according to claim 10, characterized in that the gel coating is poured into the mould to prepare the composite layer (1) with a gel coat, whereas the gel coating is impregnated with a resin and pigmented with a dye, and whereas the gel coating is applied to the surface of the mould in 1 or 2 layers by a spray method, followed by spraying a layer of resin onto the gel coat, after which, stone rubble (4) is sprinkled onto it, and as the resin layer is applied, the gel coating is monitored so it would not become hardened.
14. Method according to claims 10 and 13, characterized in that the composite layer (1) is prepared of a cement mixture that is poured into the mould onto the resin- covered gel coat, whereas the stone rubble (4) remains in the composite layer (1), followed by a reinforcement (5), which is a fibre reinforcement web, being inserted into the mixture.
15. Method as claimed in claims 10, 13 and 14, characterized in that the stone rubble (4) is marble rubble or an abrasive material with a grain size of ~1 mm and preferably of -0.5 mm.
16. Method according to any of the previous claims, characterized in that the defects of the gel coating are corrected by spraying a new layer of gel coating and the gel coating layer being polished.
17. Method according to any of the previous claims, characterized in that in order to make a decorative layer (2), textile (3) is stretched onto the composite layer (1), or no composite layer (1) is used, and after stretching, selected pattern or colour is printed or dyed onto the textile (3).
18. Method according to any of the previous claims, characterized in that the printed or dyed textile (3) is impregnated with resin to make a decorative layer (2), and the decorative layer (2) is placed on the composite layer (1) and stretched onto the composite layer (1) with a staple gun;
then, first layer of resin is applied to the textile;
air bubbles are removed by lamination;
second layer of resin is applied, a film is placed on top of it, resin is spread onto the textile (3) and underneath the film; and
after the resin hardens, film is removed and the first layer of varnish is sprayed onto the resin layer, consisting of acetone and varnish, then, a second layer of 100% varnish is sprayed.
19. Method according to the previous claim, characterized in that the resin is an acrylic resin.
20. Method according to any of the previous claims, characterized in that fire resistance fillers are added to the resin.
21. Method according to any of the previous claims, characterized in that the film is a polyester film that is planar or with a sculptured pattern and more preferably a polyethylene terephthalate (PET) resin film.
22. Method according to any of the previous claims, characterized in that heat- radiating devices are used for accelerating hardening.
23. Method according to any of the previous claims, characterized in that the decorative layer (2) is prepared using a die casting method, where air is removed with a vacuum pump after the textile is stretched onto the composite layer (1) and resin is applied under pressure onto the composite layer (1).
24. Method according to any of the previous claims, characterized in that an angle grinder with a diamond blade and a stationary pits aw, angle grinder with a control bus or abrasive waterjet cutting are used for cutting the finish plate, and the edge that is being cut is heated, whereas the cut edges are smoothed or polished.
25. Method according to any of the previous claims, characterized in that the measurements of the requested bend are marked on the finish plate on the area to be bent to make a finish plate with a bending surface;
the composite layer is cut to the depth of the reinforcement (5);
the part to be bent is heated for about 20 seconds; and
after heating, one side of the plate is bent with a smooth and slow motion to the desired angle, and the plate is fixed for about 20 seconds until the epoxy resin hardens.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
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PCT/IB2016/052301 WO2017182849A1 (en) | 2016-04-22 | 2016-04-22 | Textile decorated moisture resistant finish plate and method of producing thereof |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
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PCT/IB2016/052301 WO2017182849A1 (en) | 2016-04-22 | 2016-04-22 | Textile decorated moisture resistant finish plate and method of producing thereof |
Publications (1)
Publication Number | Publication Date |
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WO2017182849A1 true WO2017182849A1 (en) | 2017-10-26 |
Family
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PCT/IB2016/052301 WO2017182849A1 (en) | 2016-04-22 | 2016-04-22 | Textile decorated moisture resistant finish plate and method of producing thereof |
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Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN111946019A (en) * | 2020-08-25 | 2020-11-17 | 安徽森泰木塑集团股份有限公司 | Indoor LVT floor |
Citations (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JPH11324109A (en) * | 1998-05-20 | 1999-11-26 | Nitto Boseki Co Ltd | Surface covering formwork of structure |
WO2003016626A2 (en) * | 2001-08-20 | 2003-02-27 | Tepe Betopan Yapi Malzemeleri Sanayi Ve Ticaret A.S. | Coated, cement bonded wood particle boards |
US20100178822A1 (en) * | 2009-01-14 | 2010-07-15 | Michael Ketzer | Mineral-coated textile surfaces for wood materials |
-
2016
- 2016-04-22 WO PCT/IB2016/052301 patent/WO2017182849A1/en active Application Filing
Patent Citations (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JPH11324109A (en) * | 1998-05-20 | 1999-11-26 | Nitto Boseki Co Ltd | Surface covering formwork of structure |
WO2003016626A2 (en) * | 2001-08-20 | 2003-02-27 | Tepe Betopan Yapi Malzemeleri Sanayi Ve Ticaret A.S. | Coated, cement bonded wood particle boards |
US20100178822A1 (en) * | 2009-01-14 | 2010-07-15 | Michael Ketzer | Mineral-coated textile surfaces for wood materials |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN111946019A (en) * | 2020-08-25 | 2020-11-17 | 安徽森泰木塑集团股份有限公司 | Indoor LVT floor |
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