ITPS20090012A1

ITPS20090012A1 - PROCESS TO OBTAIN LARGE SHEETS OF CERAMIC, SUBTLE, GREAT DIMENSIONS, WITHOUT USE OF CLAY, OR ELEMENTS OF COMPLEX GEOMETRY, OR CABLES, OF CERAMIC CHARACTERISTICS, WITHOUT USE OF CLAY. ITEMS WITH IT OBTAINED.

Info

Publication number: ITPS20090012A1
Application number: IT000012A
Authority: IT
Inventors: Max Canti
Original assignee: Max Canti
Priority date: 2009-05-19
Filing date: 2009-05-19
Publication date: 2010-11-19

Description

PROCESSO PER OTTENERE LASTRE DI CARATTERISTICHE CERAMICHE. SOTTILI, Di GRANDI DIMENSIONI, SENZA USO DI ARGUTA. O ELEMENTI A GEOMETRIA COMPL ESSA. O CAVI, DI CARATTERISTICH CERAMICHE. SENZA USO DI ARGILLA. PROCESS TO OBTAIN SHEETS WITH CERAMIC CHARACTERISTICS. THIN, LARGE SIZE, WITHOUT THE USE OF ARGUTA. OR COMPLETE GEOMETRY ELEMENTS. OR CABLES, WITH CERAMIC CHARACTERISTICS. WITHOUT THE USE OF CLAY.

ELEMENTI CON ESSO OTTENUTE ITEMS OBTAINED WITH IT

Facclamo riferimento ad un nostro precedente; processo di cui ? stata depositata domanda di brevetti per ottenere Edemcmo lastra conglomerata o elemento di geometria complessa a cavo con matrice resinosa a secco,, che costituir? h base per la costruzione deli' elemento ceramico vero e proprio,, anche dotato di superfici vetrosa, di proiezione della decorazione. We refer to one of our precedents; process of which? patent application has been filed to obtain Edemcmo conglomerate slab or element of complex hollow geometry with dry resinous matrix, which will constitute? h basis for the construction of the actual ceramic element, also equipped with glass surfaces, for projection of the decoration.

La miscela per preparare sia l elemento conglomerato planare che di geometria complessa da destinare alla realizzazione della ceramica, sar? costituita come ne! processo precedente da polvere legante in uso nella verniciatura industriale a polveri elettrostatiche , sia di natura termoindurente che di natura termoplastica, o di altri prepolimci in polvere termoindurenti , quali resine fenoliche ureiche , melamminiche , ecc , da inette costituito da una miscela di quarzo di varie granulometrie tali da cosi ili lire un demento chiuso e vetro finemente macinato, preferibilmente proveniente da monitor di televisori o computer per il tallo che non e riciclabile per conferii turi di liquidi alimentali. The mixture to prepare both the planar conglomerate element and of complex geometry to be used for the realization of the ceramic, will be? constituted as ne! previous process from binder powder used in industrial painting with electrostatic powders, both of a thermosetting and thermoplastic nature, or of other thermosetting powder prepolymers, such as phenolic ureic resins, melamine, etc., from inettes consisting of a mixture of quartz of various granulometries such as to create a closed element and finely ground glass, preferably coming from television or computer monitors for the thallus which is not recyclable for the transfer of alimentary liquids.

La miscela viene sottoposta a compattazione secondo il processo precedente per ottenere la lastra planare di grandi dimensioni, stratificando la miscela di legante e incili iti pol vere, preriscaldando la stratificazione e snltoponcndulu a compatazione nella pressa cont?nua e cemtinuando o meno con ulteriore riscaldamento per la polimerizzazione. The mixture is subjected to compaction according to the previous process to obtain the planar slab of large dimensions, by stratifying the mixture of binder and powdered incilites, by preheating the stratification and by compacting it in the continuous press and continuing or not with further heating for polymerization.

Per ottenere elementi di geometria complessa immettiamo la miscela hi polvere in quantit? nota in slampi in uso nello stampaggio rotazionale di dementi cavi con materie plastiche, dove poi lo stampo vincolalo ad tra braccio e fatto roteare in tutte le direzioni ut un atmosfera calda prima per portare a fusione la matrice piastica e poi fallo roteare in atmosfera fredda per consolidare elemento a geometria complessa conglomerato. To obtain elements of complex geometry, we add the mixture of the powder in quantities? note in slampi in use in the rotational molding of hollow elements with plastic materials, where then the mold binds it to the arm and rotated in all directions using a hot atmosphere first to bring the piastic matrix to fusion and then rotate it in a cold atmosphere to consolidate conglomerate complex geometry element.

Successivamente gli elementi conglomerati otteouti vengono mtro?otii nel forno ceramico ed innalzali graduai mente ad una temperatura di 75-900?C dove il vetro contenuto nella miscela si trasforma allo stato plastico legando le particelle di quarzo in sostituzione del legante organico che si decompone. Subsequently, the obtained conglomerate elements are metered in the ceramic kiln and gradually raised to a temperature of 75-900 ° C where the glass contained in the mixture is transformed into the plastic state by binding the quartz particles in place of the organic binder which decomposes.

Altro metodo di formatura del ?"verde" di geometria complessa da sottoporle poi a cottura, libero nel forno ceramico, cons?ste nei preparare la matrice resinosa, inserendo nella fase di formazione, il carbone o grafite, macinando finemente la stessa m modo che ogni particella pur nella sua ridotta dimensione diventi opaca alle microonde e quindi eccitabile, preparare la miscela con inerti come nella precedente descrizione con quarzo e vetro finemente macinato, riempire una forma permeabile alle microonde e sottoporre alle stesse dopo aver compattato la miscela secca con uso di mia sorgente d? ultrasuoni, portare allo staio plastico la matrice di materia plastica dispersa intimamente e raffreddare per l estrazione. Another method of forming the "green" of complex geometry to be then fired, free in the ceramic kiln, consists in preparing the resinous matrix, inserting in the formation phase, the coal or graphite, finely grinding the same m so that each particle, even in its small size, becomes opaque to microwaves and therefore excitable, prepare the mixture with aggregates as in the previous description with quartz and finely ground glass, fill a form permeable to microwaves and subject them after compacting the dry mixture with the use of my source d? ultrasound, bring the intimately dispersed plastic matrix to the plastic bushel and cool for extraction.

Sia gli dementi planari che di geometria complessa possono essere trattati in superficie con le decorazioni e la vetrina di finitura per costituire lastre di grandi dimensioni e sonili da destinare al nvesfimcnto o calpestio, mentre quelli a geometria complessa possono essere sanitari o oggetti di uso o arredamento. Both the planar elements and those of complex geometry can be surface treated with the decorations and the finishing showcase to create large and sonic slabs to be used for nvesfimcnto or treading, while those with complex geometry can be sanitary ware or objects of use or furniture. .

Praticamenle abbiamo realizzato un materiale con le caratteristiche della vera ceramica senza usar l argilla, offrendo la possibilit? di riciclo a materiali di risulta di difficile od locazione comprendendo tra questi anche i fanghi ceramici d? risulta resi anidri per trasformarli in polvere. We have practically made a material with the characteristics of real ceramic without using clay, offering the possibility? of recycling to difficult or location waste materials including among these also the ceramic sludge d? results made anhydrous to transform them into powder.

Possono essere introdotto facoltativamente nella miscela conglomerante anche piccole quantit? di argilla m polvere o altri componenti in uso per modificare le caratteristiche finali del manufatto. Can even small quantities be optionally introduced into the conglomerating mixture? of clay m powder or other components used to modify the final characteristics of the product.

Un ulteriore scopo del presente processo di costruzione di clementi con caraneristiche ceramiche e quindi resistenti al fuoco, a partire da conglomerati ottenuti con matrice di materia plastica in polvere, ? quello d? costruire materiali isolami termici in sostituzione di elementi di lana di roccia o di verro sospettate di essere cancerogene, largamente impiegare nel navale e nell? edilizia ad elevato sviluppo verticale, pericolose soprattutto nella fase di demolizione delle navi in quanto con le vibrazioni dovute ai l'uso, il materiale tende a polverizzare, A further purpose of the present process of construction of elements with ceramic characteristics and therefore resistant to fire, starting from conglomerates obtained with a matrix of powdered plastic material,? what d? build thermal insulation materials to replace elements of rock or boar wool suspected of being carcinogenic, widely used in the naval and in the? building with high vertical development, especially dangerous in the demolition phase of ships as with the vibrations due to use, the material tends to pulverize,

il conglomerato ?verde ? sar? costituito in questo caso da sferette di vana granulometria d? vetro poroso espanso con la matrice di materia plastica che ? resa opaca alle microonde come nella descrizione procedente, sottoponendo la miscela all'anione delie microonde fondiamo al l'interno la matrice plastica legante in polvere, contrariamente non sarebbe possibile con altra fonte di eccitazione con il calore per la natura coibente della miscela stessa di vetro l'elemento conglomerato liberato dalla sua forma, planare o di geometria complessa. come quella necessaria a coibentare reti di tubi, viene introdotto libero in un ulteriore forno combinalo a microondeed aria calda, necessaria solo per non disperdere il calure dall'elemento, il riscaldamento in questo caso avviene solo sulla superiicie esterna delle sfere incapsulale di legame opaco esposte alle microonde senza portare in fusione Se stesse distruggendo la facolt? isolante dovuta alle microbollicine di aria racchiusa; azione legame s? completa curi questa azione di microonde senza la tottuta od forno ceramico, l'aria circostante viene riscaldata semplteemenle per non disperdere il udore superficiale fornito all" elemento. quindi la quantit? di calore fornita ? es?gua e mirata alia sola superficie esterna delle sferule di vetro poroso espanso, the conglomerate? green? sar? constituted in this case by small spheres of vain granulometry d? porous glass foam with the plastic matrix which? made opaque to microwaves as in the previous description, by subjecting the mixture to the anion of the microwaves we melt the plastic binding matrix into the inside, otherwise it would not be possible with other sources of excitation with heat due to the insulating nature of the glass mixture itself the conglomerate element freed from its shape, planar or of complex geometry. as that necessary to insulate networks of pipes, it is introduced free in a further furnace combined with microwaves and hot air, necessary only to not disperse the heat from the element, in this case the heating takes place only on the outer surface of the exposed opaque bond encapsulal spheres microwaves without melting If you were destroying the faculty? insulation due to the micro-bubbles of enclosed air; bond action s? complete cure this action of microwave without the tottuta or ceramic oven, the surrounding air is heated simply in order not to disperse the superficial sound supplied to the element. therefore the quantity of heat supplied is limited and aimed at the only external surface of the spherules of porous expanded glass,

l 'elemento conglomerato pu? avvenire anche ad umido incapsuli indo le particole di vetro poroso espanso con una miscela di Silicato di Sodio a 40 ?? e grafite o carbone finemente dispersi nella stessa, nel qual caso basterebbe solo seccare la miscela nella forma ma si preferisce poi suirelatreru? sformato proseguire con ulteriore trattamento alle microonde perla fusione parziale delle sferette in superfice per legare le stesse tra loro in modo irreversibile all'acqua. the conglomerate element can? even wet encapsulate the porous glass particles expanded with a mixture of Sodium Silicate at 40 ?? and graphite or coal finely dispersed in the same, in which case it would be enough to dry the mixture in the form but we prefer then suirelatreru? flan continue with further microwave treatment for the partial melting of the surface spheres to tie them together in an irreversible way to water.

I vantaggi della presente trovata sono di natura ambientale, in modo da non sconvolgere il territorio dove si trovano i giacimenti di argilla idonei, a causa dell'attivit? estrattiva , il trasporto della stessi anche a notevole distanza. The advantages of this invention are of an environmental nature, so as not to upset the territory where the suitable clay deposits are located, due to the activity? mining, the transport of the same even at a considerable distance.

l'eliminazione della preparazione dell'arglila coni le operazioni d? atomizzazione o di degasazione del rimpasto, il recti pero dei cascami di lavorazione d?lia ceramica e del granito e del vetro compresi i loro fanghi resi anidri, il recupero del vetro proveniente da monitor e computer altrimenti non riciclabile, il risparmio dell'acqua e della necessit? di depurazione, l? risparmio energetico, l ottenimento di manufatti cavi a geometria oh remodo complessa per nuovi usi quali dslemette, quando il vetro di risulta proviene da contenitori d? liquidi alimentari, per la conservazione igienica del vino o di altri liquidi alimentari in sostituzione delle cisterne in vetroresina, l ottenimento di nuovi pannelli o clementi isolanti formici in sostituzione di quelli in uso di lana di roccia o di vetro pericolosi, in sosti tu zione di materie plastiche espanse che si decompongono in caso d'incendio generando gas mortali se inalali, the elimination of the preparation of the arglila with the operations d? atomization or degassing of the reshuffle, the recti pero of ceramic and granite and glass processing waste including their anhydrous sludge, the recovery of glass coming from monitors and computers otherwise not recyclable, water saving and of the necessity? of purification, l? energy saving, obtaining hollow artifacts with a very complex geometry for new uses such as dslemette, when the resulting glass comes from containers d? food liquids, for the hygienic storage of wine or other food liquids to replace fiberglass tanks, obtaining new formic insulating panels or elements to replace those in use of dangerous rock wool or glass, in substitution of foamed plastics which decompose in the event of a fire generating fatal gases if inhaled,

Claims

CLAIMS; 1 The construction of elements with ceramic characteristics is claimed. planar without the use of clays, with the process characterized by the fact d ?: - to form a dry mixture of plastic binding powder, both of a thermosetting nature (phenolic, urea, melamine, polyester, acrylic, epoxy, polyurethane, etc. and thermoplastic. or finely marinated thermoplastic materials, in the measure from 4 to 50 %, and inerts consisting of half quartz of various granulometries such as to constitute a closed demerit and finely ground half glass or variable quantities of the two elements to combine the final characteristics to be obtained; - layering said mixture in a uniform layer on a loose aubendi carpet; - to heat said mixture until it reaches the plastic state, - compacting the hot mixture under a continuous press - to proceed with further heating for the time and temperature necessary for polymerization or not, simply proceeding for the consolidation by cooling; - whether or not to treat the surface of the conglomerate obtained with the ceramic decorations and the fine and finishing surface layer, * to introduce the so prepared elements in a ceramic kiln at the temperature between 750-900 ° C and subsequent gradual cooling, 2- The construction of ceramic elements with complex or hollow geometry, without the use of clays, is claimed with the process characterized by the fact of: - of preparing the dry mixture according to the preceding claim N1; - inserting said mixture into a rotational mold in use to obtain hollow elements or elements of complex geometry with plastic materials; to insert the mold bound to the arm and held in rotation in all directions in a hot atmosphere until and beyond the melting of the resin matrix? sa: - to insert the same mold bound to the arm and held in rotation in all directions in a cold atmosphere until the conglomerate consolidates itself; - whether or not to treat the surface of the conglomerate element obtained with the ceramic deenrarions and the surface finishing layer; - to introduce the elements thus prepared in a ceramic kiln at a temperature of between 750-900 ° C and subsequent gradual cooling down, 5- The conglomerate element obtained according to the previous claim N? 2 is claimed, aimed at use as such without further cultivation in a ceramic oven but at the temperature and time necessary for the polymerization of the thermosetting binder or simply in cooling when we use a matrix of thermoplastic material 4- The formation of the green conglomerate element with complex or planar geometries is claimed, according to the preceding claims N? 1 and N * 2. No. 3 by melting the matrix of plastic powder, generally transparent to microwaves. opaque and excitable injured with added dements, by introduction of the same in the formation phase in the thermosetting prepolymer, or in the merothermoplastic polymer, before cryomuemazionc in fine powder. so that even very small particles become opaque to microwaves due to the presence of the opacifying element, such as for example cardboard or graphite or other. 5- Does the conglomerate element obtained according to the previous claim N be claimed? 2, intended for use as such, without further cooking in a ceramic oven and without the use of microwaves, using the matrix of plastic powder transparent to the microwave and heating the rotating mold in a hot atmosphere for the time necessary for the melting to polymerization in the case d? thermosetting, first, and then in cooling immediately upon cooling in the case of thermoplastics. 6? S? claims the definition of the miscellaneous element prepared according to the preceding claim N? 4 in a ceramic combi oven with microwave to accelerate the heating phase in energy saving 7? The process of obtaining thermal insulating materials in class 0 of fire behavior is claimed, replacing the rock and glass wool used in aisles and in buildings with high vertical development, characterized by the fact: - to encapsulate globular particles of various granulometry of porous expanded glass with a prepolymer matrix of thermosetting powder or powder of thermoplastic material, made opaque to microwaves by introduction in phase d? formation of the same d? elements opacifying to the seesse: or alternatively wet with sodium silicate preferably at 40? B? additives of graphite or carbon; to form an element in the mold with a complex geometry or by layering on a carpet, mixing by melting the plastic matrix or by drying the silicate, exciting with microwaves. to subject the free-formed element to further treatment with more stringent microwaves, in a hot atmosphere in order not to disperse the surface heat of the element, until the expanded glass fuses on the surface periphery of the spheres themselves in the honeyed state, which allows irreversible welding of the same with each other. 7- The alternative use to quartz of other types of aggregates such as ceramic waste or the processing of granite or conglomerate slabs with resinous and quartz matrices is claimed (the so-called? Marble resins \ today produced in quantities exceeding 50,000,000 m 2 / year, whose waste represents a serious environmental problem) and the insertion of colored inert particles for mass decoration, 8- It is claimed that, during cooking, the organic binder of the decomposing inert particles, used starting from the same dry and in powder form, is replaced with? melted glass binder in the honey state. 9- Are the elements obtained according to the preceding claims NT 1 N claimed? 2 N.3 N? 4, N? 5. N? 6