ITPS20080023A1 - CONTINUOUS DRY CONGLOMERIZATION PROCESS WITH CONTEMPORARY ENDOWMENT, WITH DECORATIVE SURFACE FINISHING ELEMENT TO THE DECORATIVE SURFACE FINISH ELEMNTO, WITH THERMO-HARDENING ELLECTROSTATIC POWDERS IN USE IN EC PAINTING - Google Patents

Description

CONTINUOUS DRY CONGLOMERIZATION PROCESS WITH SIMULTANEOUS EQUIPMENT, TO THE ELEMENT, WITH A DECORATIVE SURFACE FINISH WITH ELECTROSTATIC THERMOSETTING POWDERS USED IN THE ECOLOGICAL DRY PAINTING FOR THE PLASTIFICATION OF METALS AND OTHER SURFACES.

ITEMS OBTAINED WITH IT.

The present found? an evolution of our previous patent application n? PS2008AQQ0Q20 entitled? Dry conglomerization process with simultaneous supply, to the element, of decorative surface finish with electrostatic thermosetting powders. Elements obtained with it ?, in which one? claimed to obtain stone slabs with a ceramic press and a drying oven at 200? C with a mixture of powdered aggregates and granules and thermosetting resins in transparent or colored powder, with also simultaneous provision of surface finishing with the use of same powders used for conglomerization.

The experimentation following the filing of the application and the certainty that this process could also be implemented with the use of a continuous press, in use in the pre-compacting of ceramic earth before? insertion in the discontinuous ceramic press, led to the drafting of this further process capable of bringing a further evolution to the previous process.

Further purpose? to have the faculty? through the continuous press d? to be able to insert an additional element performed by one or more? braked coils, constituting one or more? central armor of fiber networks to give greater resistance, safety and unbreakability? to the element, if? intended for the cladding of ventilated curtain walls in buildings with high vertical development; or a surface element that could consist of a smooth or embossed stainless steel sheet of 2/10 of a millimeter, or of other metals, to always constitute a ventilated curtain wall with the optional? to reflect the infrared heat wave in countries with high solar radiation.

Further purpose? to have the faculty? to be able to produce any required format in length without giving rise to waste in obtaining sub-formats.

Further purpose? furthermore, that of finally being able to supply the furniture industry with a thin stone conglomerate, even a few millimeters depending on the lightening, in addition to formats longer than 3050 mm. in use to avoid making joints in the worktops of modular kitchens.

A homogeneous mixture of inorganic aggregates is obtained, such as powders and granules of quartz, marble, glass, resulting ceramics or other, also in combination with each other and with the addition of decorative inclusions of greater granulometry, with the transparent or colored thermosetting powder, in use in ecological painting processes by means of electrostatic dry deposition or by gravity? through perforated screens, which mixture is ensiled for subsequent use.

For immediate use it is prepared in a mixer with the addition of

a non-staining liquid for a very light humidification,? which can? also be water how? used in the preparation of ceramic clay (operation called atomization, to avoid air pollution with inhalable dust, during transport to the point of use, and to make the mixture plastic and compactable).

Preferably we use for the purpose of the acrylic or vinyl suspensions in water to confer plasticity? and facilitate the gripping of the upper inclined plane of the continuous press.

The quantity of thermosetting powder? used in the percentage between 4% and 20% by weight, depending on the use of pure transparent resin or colored powders, the thermosetting powder can? be of the epoxy type suitable for indoor elements or of a mixed epoxy-polyester or polyester type for outdoor elements; ? It is preferable to use polyester resin for its high resistance to ultraviolet, commonly used for the surface protection of architectural metals for exteriors.

With the systems used in ceramic processing, a uniform layer of mixture is created, also by masterfully combining different colored mixtures to create marbled veins or designs in the mass, which is placed at the action of the continuous press for compacting from 50 to 00 Kg / cm2 or more.

The compacted mixture is then freely and directly subjected to the action of heat through a ventilated oven maintained at

180 ° C-200 ° C with a continuous exposure to this temperature, measured in the center of the element section, for at least 10 minutes, necessary for the polymerization of the thermosetting powder matrix.

AND? It is also possible to expose to lower temperatures in order to then be able to subsequently expose to the temperatures necessary for the thermosetting polymerization as the binder powder softens first like a thermoplastic, this allows the formation of elements to be subsequently assigned to curved or suitably shaped elements, through the use of shapes on which to recline by gravity? at the time of the thermosetting crosslinking when the suitable temperature is reached, how? used in the curvature of glass,

The cut of the fonnati in length can? to take place easily before introduction into the polymerization oven or subsequently running on the hardened plate.

Before the introduction in the oven d? polymerization? It is possible to overlap by gravity, by means of nets used for the dry decoration of majolica, the colored powders to create unique backgrounds or ornamental designs.

The process will be? equipped with the faculty? to insert in the mixture, in the phase of formation of the layer, some networks of fibers to reinforce the conglomerate slab inside, through an unwinding or more? unfold them braked; this device also allows d? carry out metal sheets of a few tenths of a millimeter on which? possible to deposit, electrostatically or by gravity, a quantity? note of thermosetting powder and subsequently stratify the mixture of incites and thermosetting powder, which after compacting and polymerization will remain perfectly anchored to the conglomerate stone material to form a functional and decorative surface.

In this case, do you proceed with the cut on the run afterwards? passing through the polymerization oven.

11 transport in the polymerization oven will be? of the type of carpet

glass-teflon perfectly tensioned on the rollers that make up the top, so that the sheet maintains perfect flatness. when the resin softens and becomes liquid before irreversibly reticulating; such carpet allows the perfect d? detabil? t? of the hardened element.

As an alternative to the fiber net decorations to increase the mechanical resistance of the element,? It is possible to disperse loose, inorganic, organic, artificial and natural free substances in the mixture.

The decorative inclusions that can then be detected by partial smoothing of the surface can be particles of greater granulometry of colored minerals, colored glass, metals, heat-resistant plastic materials such as the polycarbonate of compact discs that have the faculty? to break down the light.

The mixture can? be constituted by sludge from grinding porcelain stoneware or glass grinding, rendered anhydrous, with resin resulting from the plasticization of metals with electrostatic deposition, which ends up in the air purification filters, solving? environmental impact of two different industries and producing a conglomerate at the cost of surface decoration only.

The surface decoration carried out on the compacted slab when? effect it with powder paints, pu? be carried out later on the hardened slab by subjecting it again to the exposure of heat after having deposited the decorative powder, making the process even more? flex? bile on possibilities? of decorations.

Final surface effects can be obtained, for example chromed, with metallized powder paints, and the sheet becomes highly functional as well as highly decorative, for the optional. to reflect the infrared heat wave, when? used for curtain walls d? buildings in countries with high insolation.

Have several advantages been met with respect to the previous patent application in relation to formats, ease of use? and possibility? to insert fiber nets for internal safety reinforcements that increase their resistance and fields of application, or to obtain the plate d? any length format equipped on the surface with functional and decorative metal sheet thanks to the 1 renato unwinder of reels.

Have numerous advantages been met with respect to the stone conglomerates in use, obtained with very staining wet processes that reduce their capacity? production, both from the point of view of the safety and health of the operators and the environment which, on the other hand, are exposed to the exposure of styrene monomer and organic peroxides known to be carcinogenic.

Were additional advantages satisfied, compared to the stone conglomerates in use, with the possibility, released from the formwork, to increase the length of the slabs at will for the needs? dell? furniture industry, in addition to the faculty? of decoration in the mass with marbled veins, both for the possibility? of surface decoration that greatly enhance its use, both for the possibility? to reduce the thicknesses currently in use by 12 mm, to reduce? production and transport costs, to expand its use in light constructions, such as the elevator and naval sectors, and to facilitate handling during installation.

Claims (1)

CLAIMS I- The process of continuous formation with running cutting of the formats in length is claimed, first subjecting a mixture of powders and granules of aggregates with thermosetting powder used in the ecological dry painting of metals or other surfaces of different nature by electrostatic deposition or by deposition by gravity? from screens of appropriate caliber, to pressure in a continuous press to flexible surfaces closed in a ring, opposite each other, where the upper surface? inclined in the direction of advancement, then subsequently subjecting the compacted mixture, freely, to the action of heat, passing through a ventilated oven up to 200 ° C, exposing it to this temperature for the duration of the cross-linking of the thermosetting plastic matrix, generally about 10 minutes , by cutting the format in length or before the compacted mixture passes through the oven or after? crossing of the hardened plate itself. 0 - Do you claim the mixture formed by inerts consisting of powders and granules d? quartz, marble, glass, chamot d? ceramics, anhydrous polishing sludge, also in combination with each other, in the amount between 80 and 96% and binder powder as per the previous claim in the amount between 20% and 4%. Do they also claim? the introductions in the mixture to replace the inert part, of inclusions of granulometries close to or greater than a millimeter, colored, minerals and glass and ceramics, also mother-of-pearl, metals, mirrors, fragments of Svaroschi, heat-resistant plastics such as pol? carbonate of the resulting compact-d? sc. 3- The formation of stratification is claimed by masterfully placing mixtures of various colors to obtain marbled veins or decorations in the mass. How? used in the formation of porcelain stoneware. 4- The use of the continuous press generally used in ceramic manufacturing is claimed for the pre-compacting, at pressures between 50-100 Kg / cm2 or more, of the ceramic earth before being introduced into the discontinuous ceramic press, or similar presses, characterized from the upper fiexible plane inclined in the direction of travel. 5- In the process referred to in the preceding claims, it is claimed the use of the conveyor belt of the compacted mixture in crossing the polymerization oven consisting of glass-Teflon suitably tensioned on the motorized rollers that make up the surface, to preserve the perfect planarity. when the resinous matrix becomes liquid before reticulating. 6- Do you claim? humidification of the mixture, as per the preceding claim n? 1, before forming the stratification to be subjected first to pressure, then to heat exposure, with acrylic or vinyl suspensions in water, or other compatible adhesives, preferably 40-50%, in an additional measure of 2-5%, preferably 2%, to avoid the dispersion of the powder in the environment during the transport of the same on the conveyor belts to the place of use, and to make the mixture plastic and graspable from the upper inclined plane during compaction. Alternatively, it is claimed the humidification of the mixture with additions of liquid organic dyes, generally dispersed in polyalcohol, resistant to ultraviolet in substitution of coloring oxides and suspensions in water of prepolymers. 7- The interposition within the stratification of a network of fibers, organic or inorganic, carried out by a braked reel, positioned under tension at a suitable height so as to be crossed by the pouring of the loose mixture during the formation of the stratification to be pressed, is claimed. , to equip the element with safety reinforcement against accidental splitting. Alternatively, the use of loose fibers in the blend is claimed, 8- Is it claimed the deposition under the mixture stratification of a metal sheet of a few tenths of a millimeter, of stainless steel or anodized aluminum or other metals or alloys, smooth or embossed, suitably treated with deposition of quantities? note, 50-100 microns, of binder powder electrostatically or by gravity deposition, before the stratification of the mixture to be conglomerate, to provide it simultaneously with the formation of the stone slab d? a functional and highly decorative technical surface. 9- S? claims the deposition above the compacted mixture, before introduction into the oven d? polymerization of gravity-colored dry painting powders by means of nets, to give functional and decorative surfaces, even to ornamental designs. 10- Is it claimed that a technical and ornamental surface, also metallized to confer properties, be created at the same time as the stone conglomerization? reflection of the infrared heat wave, I 1 - The subsequent formation of the technical and ornamental glazed surface is claimed as per the previous claims no. 7 and no. 8 on the previously polymerized slab or on real ceramic biscuits to replace the third fire in energy saving and enormous expansion of capacity. decorative and functional. 12- Partial firing of the compacted mixture is claimed, even with the possible overlapping of the surface paint, without reaching the thermosetting polymerization temperatures, in order to subsequently treat the plate, positioned on curved or shaped methane molds at increasing temperatures up to that of polymerization , during which it softens by adapting to gravity? to the mold, like the processes in use for? curved glass. 13- The elements formed according to the previous claims and descriptions are claimed, characterized by the fact that they have been obtained continuously from a mixture of inerts and thermosetting powders used in the surface plasticization of metals or other materials, made slightly humid with suspensions in water of prepolymers, compacted at pressures between 50-100 Kg / cm2 or more, in a continuous press, used in the pre-compacting of ceramic earth before? introduction into the press, or similar for other uses with the upper plane inclined in the direction of advancement and subjected to the action of heat around 170-200 ° C for at least 10 minutes necessary for the thermosetting polymerization, with or without further surface deposition of powder of colored or transparent dry painting with additives to increase the surface resistance, with or without the mesh of reinforcing fibers, with or without the provision of surface metal sheets. 14- The curved or shaped elements formed according to the preceding claim n? 12 are claimed.