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WO2009005384A2 - Procédé pour la production de panneaux de parement formés par un aggloméré de minéraux et d'agrégats spéciaux mélangés avec un adhésif à deux composants et/ou des résines thermodurcissables - Google Patents

Procédé pour la production de panneaux de parement formés par un aggloméré de minéraux et d'agrégats spéciaux mélangés avec un adhésif à deux composants et/ou des résines thermodurcissables Download PDF

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Publication number
WO2009005384A2
WO2009005384A2 PCT/PT2008/000027 PT2008000027W WO2009005384A2 WO 2009005384 A2 WO2009005384 A2 WO 2009005384A2 PT 2008000027 W PT2008000027 W PT 2008000027W WO 2009005384 A2 WO2009005384 A2 WO 2009005384A2
Authority
WO
WIPO (PCT)
Prior art keywords
board
stepped
silos
granules
compound
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.)
Ceased
Application number
PCT/PT2008/000027
Other languages
English (en)
Other versions
WO2009005384A3 (fr
Inventor
Marco Sutil Saraiva
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Labicer - Laboratorio Industrial Ceramico Sa
Original Assignee
Labicer - Laboratorio Industrial Ceramico Sa
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Labicer - Laboratorio Industrial Ceramico Sa filed Critical Labicer - Laboratorio Industrial Ceramico Sa
Publication of WO2009005384A2 publication Critical patent/WO2009005384A2/fr
Publication of WO2009005384A3 publication Critical patent/WO2009005384A3/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C67/00—Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00
    • B29C67/24—Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00 characterised by the choice of material
    • B29C67/242—Moulding mineral aggregates bonded with resin, e.g. resin concrete
    • B29C67/243—Moulding mineral aggregates bonded with resin, e.g. resin concrete for making articles of definite length
    • 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
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
    • Y02W30/00—Technologies for solid waste management
    • Y02W30/50—Reuse, recycling or recovery technologies
    • Y02W30/91—Use of waste materials as fillers for mortars or concrete

Definitions

  • a process for the production of panels for cladding formed by a conglomerate of minerals and special aggregates mixed with two- component adhesive and/or thermosetting resins.
  • the present invention relates to a product consisting in a panel formed by a conglomerate of minerals and special aggregates from the residues and waste of the ceramic industry agglomerated with one another and compacted with ic thermosetting resins and two-component adhesive and to the respective industrial process for the production of panels in a compact of minerals and special aggregates with characteristic and differentiating design and technical features, either in its composition or in its painting and finishing, and which is intended for use in paving and cladding in general,
  • the inventor is a company that manufactures cladding products for floors, walls and other surfaces and has developed its own new product, called Vitrakem, and the process for obtaining it, which, although having common elements to other known processes it has a different concept to such known processes, since this product does not contain ceramic elements and consists in L : the exclusive use of residues and waste originating from the industrial production of other products, namely ceramics, plastic, iron, which are then compacted and agglomerated by the process object of the present invention, which having been developed by the inventor allows the industrial production of this product.
  • the object of the present invention consists in a board, plate or panel with excellent technical features adapted to use in cladding for a wide range of surfaces and its manufacturing process.
  • the concept for this new product rests on the recovery of production surpluses from the ceramic industry, the waste
  • the new product has good mechanical strength, fire-resistance due to its low percentage in adhesive, resistance to the attack of chemical cleaning products i ⁇ , and other similar products, as well as to stains from a wide range of commonly used products, which together with its decorative effect allowing the contemplation of a wide range of architectures allow this product to be used with unmistakable advantages in a wide range of applications in construction.
  • Other raw materials susceptible of providing insulating properties, among others, can be easily added to this new product, as well as pin or die application systems similar to those used in floating panels. This simplifies its application, making it a desirable solution.
  • Granules of a wide range of raw materials and decorative elements namely aluminium, copper, plastic, mother-of-pearl, acrylic, among others, within ib several silos and hoppers (Fig. 1), are mixed with a two-component adhesive and/or with thermosetting resins, then driven (Fig. 1) through a dosing machine towards a mat (Fig. 2), with the approximate width of the final plate, where the material resulting from the mixture is distributed with uniform thickness which is yet far from the final thickness. It is then subjected to continuous pre- compression (Fig, 3), producing a substrate that is close to the final size and with
  • D a density also similar to the final density.
  • the process of aggregating all the components making up the substrate is obtained by stepped cold pressing (Fig. 3), producing a plate now having a consistency, size and thickness similar to that of the end product.
  • the forming process for the substrate ends by subjecting the plate or panel, now pressed and shaped, to a suitable temperature comprised
  • the plates obtained can be of different sizes and thickness by varying the sizes of the mould the special aggregates are placed in during the phase following continuous pre-compression.
  • the surfaces of the plate obtained by this forming and pre-compression process are subsequently treated by a calibration process (Fig. 5) and a subsequent process of applying a coating (Fig. 6) that allows seeing the substrate forming the board or panel, or uniform coloured coatings, or coatings with effects imitating marble, granite, stone, wood and any other coating
  • the product obtained consisting in compact plates or panels of minerals and special aggregates can be used as cladding for interiors or outboards for walls or in any kind of structure requiring cladding, flooring, floor boards, and as a decorative element for interior or outdoor spaces.
  • This product despite having excellent mechanical strength, can be cut s c. easily to specific sizes so that it can be placed where intended without the need for cutting machines that must comply with special technical specifications.
  • Figure 3 - illustrates the diagram of the pre-compression and stepped t pressing process.
  • FIG. 1 illustrates the complete diagram of the board composition process, clearly showing the existence of silos, transporters, hoppers, mixers, adhesive pump, pre-compression system, press, dryer/polyrneriser, and mobile framework.
  • Figure 2 illustrates a partial diagram of the mixture preparation process
  • Figure 3 illustrates a partial diagram of the pre-compression and stepped cold pressing process, showing that the mixture from the mixers is placed in a
  • Figure 4 illustrates the drying and polymerisation process, showing that after pressing the panel is placed on trays and introduced in the dryer/polymeriser.
  • Figure 5 illustrates the diagram for surface calibration, showing that the panel, having been matured in the previous process, is passed through several surface calibration machines that will produce a panel of perfectly calibrated thickness.
  • Figure 6 illustrates the diagram for surface finishing, showing that the
  • -5 c panel is given several coatings in order to improve the technical features of its surface, as well as the application of a colour coating that can be continuous, stepped or graphic.
  • position number 1 indicates one of the silos where the different granules of raw materials to be agglomerated are placed.
  • Several silos can be used for a wide range of raw materials to be used in the agglomeration process, guaranteeing separation of the elements of the composition during preparation, After receiving the different waste or surplus granules and having placed them in the silos (1), these are transported via belts b (2) to smaller intermediate silos (3).
  • the introduction of the two-component adhesive and/or thermosetting resin inside the mixer (4) is performed by a high-pressure pump system (5) having on one end a continuous mixing head where the products that are
  • the granules could still have colouring added to it in order to colour the paste, as well as added waste/surplus from elements such as mother-of-pearl, aluminium, copper, plastic, acrylic among others, which would be decorative components.
  • the thickness of the substrate in this phase still has measurements that are far from the final measurements and is not solid.
  • a pre-compression system by means of rollers (9) is used in order to exert continuous pressure on the substrate, ensuring that as well as being
  • 3C homogenously distributed, it has a density and thickness close to those of the end product, as well as sufficient solidity in order to be cut and transported by means of a belt (10) inside of the stepped press (11).
  • Material deposition systems can be introduced prior to the use of this system, or even afterwards, in order to achieve varied decorative effects on the substrate.
  • the stepped press (11) After receiving the substrate the stepped press (11) applies cold pressing, thus volumetrically conforming the part and guaranteeing that it will have sufficient strength for unmoulding and handling. Both sides of the part, being either smooth or with relief, are established by the structure of the dies placed inside the mould in the stepped press (11). After this conformation process the "Board, plate or panel” product is removed from inside the press (11) and placed 5 at the inlet of the dryer/polymeriser (12).
  • the dryer/polymeriser (12) remains inside at a controlled temperature that is capable of bringing the part to the desired levels of hardening and flexibility. Having finished the continuous cycle of subjecting the "Board" part to temperature, thus generating the polymerisation reaction, the part is removed to io mobile storage (13) where it will remain in storage. The part is at this moment very malleable, since it hardens proportionally to its decrease in temperature.
  • the surface finishing of the boards ( Figure 6), which may be adapted to i c other types of three-dimensional supports, is a process that allows applying surface coatings to the product in a simple, cost-effective, fast and effective manner that can be dynamic, by modifying the number of machines in series and/or modifying the arrangement thereof.
  • These coatings can range from transparent coatings that allow seeing the support, to continuous, stepped or
  • This process is started with a superficial cleaning of the "Board, plate or panel” product (18) so that the filling product (19) can subsequently be applied, which is dried in a drying chamber (20). Between applications the product applied must be dried, either by means of drying chambers, which can be by infrared, mercury, ultraviolet, hot air, among others, according to the product to be dried. t The application of other products providing colour or transparencies to the new product must be performed in the machine (21), and repeated as many times as necessary. The flexibility in the application line allows easily introducing a number of machines for each specific application requirement.
  • the design battery (23) can be as many as necessary so that a wide range of designs can be transferred onto the product with the best resolutions.
  • the technologies used for these design processes are similar to screen printing processes but also to more technologically advanced processes
  • f such as laser, laserjet or inkjet printing.
  • the application at the end of this process (24) will provide features of resistance to abrasion and chemicals, among others, ensuring that the support and the different screen-printing applications are not damaged.

Landscapes

  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Ceramic Engineering (AREA)
  • Structural Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Materials Engineering (AREA)
  • Organic Chemistry (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)
  • Press-Shaping Or Shaping Using Conveyers (AREA)

Abstract

La présente invention concerne un procédé pour la production d'une plaque ou d'un panneau formé exclusivement par le résultat de l'agglomération et du compactage de minéraux sélectionnés et d'agrégats spéciaux provenant du surplus ou de résidus de l'industrie céramique avec des adhésifs à deux composants qui sont le résultat du mélange de deux résines et/ou de résines thermodurcissables différentes, au sein de l'industrie des agglomérés en résine. Au cours de ce procédé, les résidus sont stockés dans des silos (1), transportés par l'intermédiaire de courroies (2) jusqu'à des silos intermédiaires (3) d'où ils sont distribués à des mélangeurs discontinus (4) dans lesquels est ajouté l'adhésif à deux composants par l'intermédiaire d'une pompe de dosage (5) pour former un composé. Après l'homogénéisation, le composé est transporté par l'intermédiaire de courroies (6) et placé sur une machine de dosage (7), qui le distribue sur une courroie (8) où il est comprimé dans des rouleaux (9), transporté par l'intermédiaire d'une courroie (10) dans la presse (11) où il est pressé à froid, puis envoyé au séchoir (12), où il durcit et d'où il est placé dans un stockage mobile (13) afin d'obtenir les spécifications nécessaires dans un produit final haut de gamme pour le pavement et le parement.
PCT/PT2008/000027 2007-07-05 2008-07-04 Procédé pour la production de panneaux de parement formés par un aggloméré de minéraux et d'agrégats spéciaux mélangés avec un adhésif à deux composants et/ou des résines thermodurcissables Ceased WO2009005384A2 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
PT103777A PT103777A (pt) 2007-07-05 2007-07-05 Processo para a produção de painéis para revestimentos constituídos por um aglomerado de minerais e inertes qualificados misturados com adesivo bicomponente e ou resinas termoendurecedoras
PT103777 2007-07-05

Publications (2)

Publication Number Publication Date
WO2009005384A2 true WO2009005384A2 (fr) 2009-01-08
WO2009005384A3 WO2009005384A3 (fr) 2009-05-14

Family

ID=39884944

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/PT2008/000027 Ceased WO2009005384A2 (fr) 2007-07-05 2008-07-04 Procédé pour la production de panneaux de parement formés par un aggloméré de minéraux et d'agrégats spéciaux mélangés avec un adhésif à deux composants et/ou des résines thermodurcissables

Country Status (2)

Country Link
PT (1) PT103777A (fr)
WO (1) WO2009005384A2 (fr)

Family Cites Families (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2126538A5 (en) * 1971-02-10 1972-10-06 Lille Inst Catholiqu Abrasion-resistant tiles prodn - from ceramic grit and polyester or epoxy resins
KR20020051443A (ko) * 2000-12-22 2002-06-29 이일희 폐석회와 건축폐자재를 이용한 토목, 건축자재 제조방법
ITPS20010017A1 (it) * 2001-05-24 2002-11-24 Canti & Figli Srl Procedimento atto ad ottenere pannelli piastrelle e simili con agglomerati minerali vari ed eventuale aggiunta di gomma o materie plastiche

Also Published As

Publication number Publication date
PT103777A (pt) 2008-01-07
WO2009005384A3 (fr) 2009-05-14

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