GB2231881A - Moulded articles of resin-bonded stone particles - Google Patents
Moulded articles of resin-bonded stone particles Download PDFInfo
- Publication number
- GB2231881A GB2231881A GB9008039A GB9008039A GB2231881A GB 2231881 A GB2231881 A GB 2231881A GB 9008039 A GB9008039 A GB 9008039A GB 9008039 A GB9008039 A GB 9008039A GB 2231881 A GB2231881 A GB 2231881A
- Authority
- GB
- United Kingdom
- Prior art keywords
- resin
- product
- stone
- powdered
- weight
- Prior art date
- Legal status (The legal status 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 status listed.)
- Withdrawn
Links
- 239000004575 stone Substances 0.000 title claims abstract description 20
- 239000002245 particle Substances 0.000 title claims abstract description 12
- 229920005989 resin Polymers 0.000 claims abstract description 11
- 239000011347 resin Substances 0.000 claims abstract description 11
- 239000010438 granite Substances 0.000 claims abstract description 5
- 238000000034 method Methods 0.000 claims description 5
- 239000000203 mixture Substances 0.000 claims description 4
- 238000000465 moulding Methods 0.000 claims description 4
- 229920001225 polyester resin Polymers 0.000 claims description 3
- 239000004645 polyester resin Substances 0.000 claims description 3
- 239000000428 dust Substances 0.000 claims description 2
- 239000004033 plastic Substances 0.000 claims description 2
- 238000009747 press moulding Methods 0.000 claims description 2
- 239000011342 resin composition Substances 0.000 claims description 2
- 239000010454 slate Substances 0.000 description 4
- VTYYLEPIZMXCLO-UHFFFAOYSA-L Calcium carbonate Chemical compound [Ca+2].[O-]C([O-])=O VTYYLEPIZMXCLO-UHFFFAOYSA-L 0.000 description 2
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 2
- CPLXHLVBOLITMK-UHFFFAOYSA-N Magnesium oxide Chemical compound [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 description 2
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 2
- 239000003054 catalyst Substances 0.000 description 2
- 229920001187 thermosetting polymer Polymers 0.000 description 2
- 235000008733 Citrus aurantifolia Nutrition 0.000 description 1
- 235000019738 Limestone Nutrition 0.000 description 1
- KWYUFKZDYYNOTN-UHFFFAOYSA-M Potassium hydroxide Chemical compound [OH-].[K+] KWYUFKZDYYNOTN-UHFFFAOYSA-M 0.000 description 1
- CDBYLPFSWZWCQE-UHFFFAOYSA-L Sodium Carbonate Chemical compound [Na+].[Na+].[O-]C([O-])=O CDBYLPFSWZWCQE-UHFFFAOYSA-L 0.000 description 1
- 235000011941 Tilia x europaea Nutrition 0.000 description 1
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 1
- 229910000019 calcium carbonate Inorganic materials 0.000 description 1
- 239000003795 chemical substances by application Substances 0.000 description 1
- 150000001875 compounds Chemical class 0.000 description 1
- 230000005484 gravity Effects 0.000 description 1
- 239000004615 ingredient Substances 0.000 description 1
- 229910052742 iron Inorganic materials 0.000 description 1
- 239000004571 lime Substances 0.000 description 1
- 239000006028 limestone Substances 0.000 description 1
- 239000000395 magnesium oxide Substances 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 239000004579 marble Substances 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 150000002978 peroxides Chemical class 0.000 description 1
- 229940072033 potash Drugs 0.000 description 1
- BWHMMNNQKKPAPP-UHFFFAOYSA-L potassium carbonate Substances [K+].[K+].[O-]C([O-])=O BWHMMNNQKKPAPP-UHFFFAOYSA-L 0.000 description 1
- 235000015320 potassium carbonate Nutrition 0.000 description 1
- 230000003014 reinforcing effect Effects 0.000 description 1
- 239000000377 silicon dioxide Substances 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 229920003002 synthetic resin Polymers 0.000 description 1
- 239000000057 synthetic resin Substances 0.000 description 1
Classifications
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B26/00—Compositions of mortars, concrete or artificial stone, containing only organic binders, e.g. polymer or resin concrete
- C04B26/02—Macromolecular compounds
- C04B26/10—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
- C04B26/18—Polyesters; Polycarbonates
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C1/00—Building elements of block or other shape for the construction of parts of buildings
- E04C1/40—Building elements of block or other shape for the construction of parts of buildings built-up from parts of different materials, e.g. composed of layers of different materials or stones with filling material or with insulating inserts
-
- 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
- E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
- E04C2/04—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
- C04B2111/54—Substitutes for natural stone, artistic materials or the like
Landscapes
- Engineering & Computer Science (AREA)
- Architecture (AREA)
- Chemical & Material Sciences (AREA)
- Structural Engineering (AREA)
- Civil Engineering (AREA)
- Ceramic Engineering (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Materials Engineering (AREA)
- Organic Chemistry (AREA)
- Compositions Of Macromolecular Compounds (AREA)
- Macromonomer-Based Addition Polymer (AREA)
Abstract
A moulded article, for example a roofing tile, comprises particles of a natural stone (preferably granite) bonded by means of a cured resin.
Description
MOULDED ARTICLES
The present invention relates to the production of moulded articles, particularly (but not necessarily exclusively) for use as roofing tiles for buildings.
It is well established practice to clad the rooves of buildings with slates. However, natural slate is becoming increasingly difficult to obtain and may be too expensive for certain applications.
GB-B-2 041 959 proposes a slate roofing tile which comprises slate particles bonded with a thermosetting resin into a unitary product of the desired shape and size. However, once again the product relies on the use of slate.
According to the present invention there is provided a moulded article which comprises particles of a natural stone bonded by means of a cured resin.
The invention also provides a method of producing a moulded article comprising admixing natural stone particles with a curable resin composition, moulding the mixture to a desired shape, and curing the resin.
Preferably the product comprises 75 to 85% by weight of the powdered stone, most preferably about 80%. The powdered stone may for example have a particle size up to 2mm.
It is preferred that at least 40% (more preferably at least 45% by weight) of the powdered stone contents should be in the form of a dust which passes through a 75 micron (200 mesh) sieve. Such volume fraction is preferred because the particulate stone may be readily formed into a plastic compound by admixture with the synthetic resin.
Depending on the type of stone used, the particle size and particle size fraction can be adjusted to provide for maximum reinforcing effect, maximum density and lowest cost. When correctly formulated the compounded ingredients will flow as a homogeneous mass under the action of heat and pressure and cure to an infusible solid, between matched metal tools into the desired shape.
The preferred stone is granite on account of its relative cheapness and the strength which it imparts to the moulded article.
The granite may for example have a specific gravity of 2.64 and be generally of the following analysis,
Silica 70%
Alumina 16%
Peroxide of iron 2.71%
Lime 1.76%
Magnesia 1.2% Potash 5.42%
Soda 3.07%
Other natural stones which could be used include sandstone, limestone, Portland stone and marble.
The curable resin is preferably a thermosetting resin, most preferably a polyester resin. Catalysts and promoters of know types may be incorporated in the resin to facilitate curing.
Most preferably, the moulding is effected by a hot press moulding operation using a closed chamber mould. A suitable temperature range is 120-1250C with a pressure of 80-lOOpsi.
In a preferred embodiment of the invention, a roofing tile is prepared by admixing ca 80% by weight of granite particles with ca 1718% of a polyester resin and a balance of calcium carbonate, catalysts and mould release agent. The mixture is then hot pressed using the aforementioned temperatures and pressures in a closed cavity mould so as to produce a roofing tile of the desired dimensions.
Claims (11)
1. A moulded article which comprises particles of a natural stone bonded by means of a cured resin.
2. A product as claimed in claim 1 comprising 75 to 85% by weight of the powdered stone.
3. A product as claimed in claim 2 comprising about 80% by weight of the powdered stone.
4. A product as claimed in any one of claims 1 to 2 wherein the powdered stone has a maximum particle size of 2mm.
5. A product as claimed in any one of claims 1 to 4 wherein the powdered stone comprises at least 40% by weight of a dust which passes through a 75 micron screen.
6. A product as claimed in any one of claim 1 to 5 wherein the powdered stone comprises granite.
7. A product as claimed in any one of claim 1 to 6 in the form of a roofing tile.
8. A method of producing a moulded article comprising admixing natural stone particles with a curable resin composition, moulding the mixture to a desired shape and curing the resin.
9. A method as claimed in claim 8 wherein the resin is a polyester resin.
10. A method as claimed in claim 8 or 9 wherein the moulding is effected by a hot press moulding operation.
11. A method as claimed in any one of claims 8 to 10 wherein the powdered stone is admixed with the curable resin to form a plastic composition prior to curing.
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| GB898907945A GB8907945D0 (en) | 1989-04-08 | 1989-04-08 | Moulded articles |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| GB9008039D0 GB9008039D0 (en) | 1990-06-06 |
| GB2231881A true GB2231881A (en) | 1990-11-28 |
Family
ID=10654683
Family Applications (2)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| GB898907945A Pending GB8907945D0 (en) | 1989-04-08 | 1989-04-08 | Moulded articles |
| GB9008039A Withdrawn GB2231881A (en) | 1989-04-08 | 1990-04-09 | Moulded articles of resin-bonded stone particles |
Family Applications Before (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| GB898907945A Pending GB8907945D0 (en) | 1989-04-08 | 1989-04-08 | Moulded articles |
Country Status (1)
| Country | Link |
|---|---|
| GB (2) | GB8907945D0 (en) |
Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| EP0626216A1 (en) * | 1993-05-28 | 1994-11-30 | Terra Ijssel B.V. | Method for working up waste materials |
| ES2148027A1 (en) * | 1997-04-15 | 2000-10-01 | Maquinaria Jumilla S L | Building roof stamped steel based construction element includes a fungicidal and fire resistant coating on intermediate epoxy polyester and e.g. marble layers |
| GB2360039A (en) * | 2000-03-07 | 2001-09-12 | Magicmatch Ltd | Filler compound |
| WO2004039564A1 (en) * | 2002-10-31 | 2004-05-13 | Eco New Technology Llc | Method for manufacturing elements from powders and granules |
Citations (11)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB774674A (en) * | 1951-06-20 | 1957-05-15 | Hoechst Ag | Manufacture of cold-setting compositions yielding chemically resistant solid masses |
| GB921965A (en) * | 1960-02-23 | 1963-03-27 | Btr Industries Ltd | An article of artificial granite or granite substitute |
| US3278662A (en) * | 1965-11-17 | 1966-10-11 | Lee R Mangrum | Process for making tile embodying stone particles |
| GB1244857A (en) * | 1967-12-06 | 1971-09-02 | Repla Sa | Method for making panels of the artificial stone-type and products so produced |
| GB1404934A (en) * | 1971-07-16 | 1975-09-03 | Zacaroli H L | Decorative tiles and methods of making them |
| GB2052471A (en) * | 1979-06-22 | 1981-01-28 | Fijon Ltd | Artificial granite |
| US4299761A (en) * | 1979-03-19 | 1981-11-10 | Rohm And Haas Company | Polymer concrete compositions, methods of application thereof, and polymerized products thereof |
| GB2157704A (en) * | 1984-02-14 | 1985-10-30 | E H Bradley Building Products | Building materials; artificial slate |
| GB2157673A (en) * | 1984-04-19 | 1985-10-30 | Ronald Parry | Improvements relating to the manufacture of porous articles |
| GB2197673A (en) * | 1986-11-12 | 1988-05-25 | Harris Frederick Brian Oatway | Simulated natural stone panels |
| EP0292628A2 (en) * | 1987-05-25 | 1988-11-30 | Panayiotis Stavrakellis | Synthetic wood composition from fruit kernels or shells and/or marble chips |
-
1989
- 1989-04-08 GB GB898907945A patent/GB8907945D0/en active Pending
-
1990
- 1990-04-09 GB GB9008039A patent/GB2231881A/en not_active Withdrawn
Patent Citations (11)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB774674A (en) * | 1951-06-20 | 1957-05-15 | Hoechst Ag | Manufacture of cold-setting compositions yielding chemically resistant solid masses |
| GB921965A (en) * | 1960-02-23 | 1963-03-27 | Btr Industries Ltd | An article of artificial granite or granite substitute |
| US3278662A (en) * | 1965-11-17 | 1966-10-11 | Lee R Mangrum | Process for making tile embodying stone particles |
| GB1244857A (en) * | 1967-12-06 | 1971-09-02 | Repla Sa | Method for making panels of the artificial stone-type and products so produced |
| GB1404934A (en) * | 1971-07-16 | 1975-09-03 | Zacaroli H L | Decorative tiles and methods of making them |
| US4299761A (en) * | 1979-03-19 | 1981-11-10 | Rohm And Haas Company | Polymer concrete compositions, methods of application thereof, and polymerized products thereof |
| GB2052471A (en) * | 1979-06-22 | 1981-01-28 | Fijon Ltd | Artificial granite |
| GB2157704A (en) * | 1984-02-14 | 1985-10-30 | E H Bradley Building Products | Building materials; artificial slate |
| GB2157673A (en) * | 1984-04-19 | 1985-10-30 | Ronald Parry | Improvements relating to the manufacture of porous articles |
| GB2197673A (en) * | 1986-11-12 | 1988-05-25 | Harris Frederick Brian Oatway | Simulated natural stone panels |
| EP0292628A2 (en) * | 1987-05-25 | 1988-11-30 | Panayiotis Stavrakellis | Synthetic wood composition from fruit kernels or shells and/or marble chips |
Cited By (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| EP0626216A1 (en) * | 1993-05-28 | 1994-11-30 | Terra Ijssel B.V. | Method for working up waste materials |
| US5656674A (en) * | 1993-05-28 | 1997-08-12 | Terra Ijssel B.V. | Method for working up waste materials |
| ES2148027A1 (en) * | 1997-04-15 | 2000-10-01 | Maquinaria Jumilla S L | Building roof stamped steel based construction element includes a fungicidal and fire resistant coating on intermediate epoxy polyester and e.g. marble layers |
| GB2360039A (en) * | 2000-03-07 | 2001-09-12 | Magicmatch Ltd | Filler compound |
| WO2004039564A1 (en) * | 2002-10-31 | 2004-05-13 | Eco New Technology Llc | Method for manufacturing elements from powders and granules |
Also Published As
| Publication number | Publication date |
|---|---|
| GB8907945D0 (en) | 1989-05-24 |
| GB9008039D0 (en) | 1990-06-06 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| 732 | Registration of transactions, instruments or events in the register (sect. 32/1977) | ||
| WAP | Application withdrawn, taken to be withdrawn or refused ** after publication under section 16(1) |