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GB2041959A - Slate-filled resin products - Google Patents

Slate-filled resin products Download PDF

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Publication number
GB2041959A
GB2041959A GB8003715A GB8003715A GB2041959A GB 2041959 A GB2041959 A GB 2041959A GB 8003715 A GB8003715 A GB 8003715A GB 8003715 A GB8003715 A GB 8003715A GB 2041959 A GB2041959 A GB 2041959A
Authority
GB
United Kingdom
Prior art keywords
slate
mixture
resin
mould
tile
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.)
Granted
Application number
GB8003715A
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GB2041959B (en
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Individual
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Individual
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Filing date
Publication date
Application filed by Individual filed Critical Individual
Publication of GB2041959A publication Critical patent/GB2041959A/en
Application granted granted Critical
Publication of GB2041959B publication Critical patent/GB2041959B/en
Expired legal-status Critical Current

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Classifications

    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04DROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
    • E04D1/00Roof covering by making use of tiles, slates, shingles, or other small roofing elements
    • E04D1/12Roofing elements shaped as plain tiles or shingles, i.e. with flat outer surface
    • E04D1/22Roofing elements shaped as plain tiles or shingles, i.e. with flat outer surface of specified materials not covered by any one of groups E04D1/14 - E04D1/205, or of combinations of materials, where at least one is not covered by any one of groups E04D1/14 - E04D1/205
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B14/00Use of inorganic materials as fillers, e.g. pigments, for mortars, concrete or artificial stone; Treatment of inorganic materials specially adapted to enhance their filling properties in mortars, concrete or artificial stone
    • C04B14/02Granular materials, e.g. microballoons
    • C04B14/04Silica-rich materials; Silicates
    • C04B14/10Clay
    • C04B14/108Shale, slate
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B26/00Compositions of mortars, concrete or artificial stone, containing only organic binders, e.g. polymer or resin concrete
    • C04B26/02Macromolecular compounds
    • C04B26/10Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
    • C04B26/18Polyesters; Polycarbonates
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08KUse of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K3/00Use of inorganic substances as compounding ingredients
    • C08K3/34Silicon-containing compounds

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Structural Engineering (AREA)
  • Organic Chemistry (AREA)
  • Civil Engineering (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Architecture (AREA)
  • Materials Engineering (AREA)
  • Health & Medical Sciences (AREA)
  • Medicinal Chemistry (AREA)
  • Polymers & Plastics (AREA)
  • Dispersion Chemistry (AREA)
  • Compositions Of Macromolecular Compounds (AREA)
  • Reinforced Plastic Materials (AREA)

Abstract

Slate products, such as slate roofing tiles, are formed by mixing slate particles in the form of powder of small slivers with a thermosetting, e.g. polyester, resin and allowing the mixture to set in a mould. To improve impact resistance and to reduce risk of shattering a reinforcement such as a glass fibre mat or plastics mesh can be included.

Description

SPECIFICATION Slate products The present invention concerns slate products and a method of forming same. In particular the invention concerns slate roofing tiles.
According to one aspect of the present invention a method of forming a slate product comprises mixing slate particles, as herein defined, with a thermosetting resin and allowing the mixture to set into a desired shape and size.
According to another aspect of the present invention a slate product comprises slate patiles bonded with a thermosetting resin into a unitary product of a desired shape and size.
The term "slate particles" as employed herein includes slate dust or powder and also slivers, chips or fragments of slate having a variety of sizes.
In the production of roofing tiles, slate particles are mixed with a thermosetting polyester resin and the mixture, in the form of a thick slurry, can be allowed to set in a mould.
Thus individual roofing slates can be formed by a moulding process and in a production line. Alternatively, the mixture can be spread as a sheet or layer having a required thickness which is allowed to set and can then be cut into smaller portions of any required shape and size. The mixture of slate particles and resin can be allowed to set at ambient temperature in a so-called cold moulding process.
Preferably a vibratory mould is used to provide a substantially uniform distribution of the mixture over the mould and the mould can be coated with a release agent. As an alternative to the cold moulding process it is possible to employ a press or the like to stamp the mixture into a required shape and size.
A mixture can comprise by weight in the region of 80% slate particles and 20% resin.
At present a preferred mixture comprises about 86% by weight slate particles and about 14% by weight resin. The ratio is variable and can be determined by trial and experiment as the amount of resin required will depend upon, amongst other things, the size of the slate particles. In general, the smaller the size of the slate particles the more resin is required for bonding. A number of proprietary resins are available and are suitable for the present invention. It is not possible to list and include all the available thermosetting resins and again this can be readily determined by simple trial and experiment.
The slate particles can be in powder or dust form or can be in the form of slivers, chips or granules having a variety of sizes but gener ally not exceeding about i inch for the prod 4 uction of roofing tiles. Whereas the resin can bond slate particles of larger size into a unitary structure there is a limit to the maximum size of particle that can be used for forming a thickness of the roofing tile and clearly the maximum dimension of individual slate particles cannot exceed the required thickness of the tile to be produced. A standard roofing tile can be 20 inches by 10 inches and have a thickness of about 1/8 inch and usually not more than 3/16 inch. For such a tile the major dimension of individual slate particles must not about 1/8 inch and this can be determined and controlled by sieve screens.
A slate roofing tile formed from a mixture of individual slate particles and a thermosetting resin bonding agent is a rigid structure which is substantially lighter in weight than a natural slate tile of the same dimensions, The resin composite tile can however shatter or fracture if dropped or if a heavy object falls on to it This can be overcome by introducing a reinforcement into the mixture during the moulding stage whereby to make the finished tile substantially shatterproof. The reinforcement can take a number of forms, for example, a mat or layer of glass fibres can be introduced into the mould with the slate particles and resin. Alternatively, the reinforcement can be a metal mesh or a plastics mesh such a nylon.
Further possible reinforcements can be paper in sheet or shredded form and timber shavings. The reinforcement, whatever its form, serves to absorb and distribute in pact shocks over the whole area of the tile and thereby reduces the possibility of the tile shattering under impact forces.
The invention will be described in further detail with reference to the following example.
A standard roofing tile can have dimensions 20 x 20 x 1/8 inch. Thus to form such a tile according to the invention slate particles and a thermosetting resin are introduced into a mould of the appropriate dimensions and the mould is vibrated or shaken to obtain an even distribution of the mixture over the surface area of the mould and to a depth of approximately 1/8 inch. By calculation and with practice an operator can judge the amount of mixture required in the mould to give the required thickness of tile. A thin layer of the slate/resin mixture can be introduced into the mould to be immediately followed by a layer of reinforcement such as fibreglass or woven mesh and this is then covered by the remainder of the slate/resin mixture. Alternatively, the reinforcement can be introduced into the mixture immediately after all the mixture has been introduced into the mould.The mould is vibrated and the mixture is allowed to set at ambient temperature. The tile is then ejected from the mould and is in a finished state.
Thermosetting polyester resins are brought to their final cured state by a catalyst. A generally used resin is styrene monomer and the catalyst reacts with the styrene monomer to produce a cross-linked polymer. The catalyst can be mixed with the resin prior to introduction into the mould or can be added separately into the mould. Usual catalysts are organic peroxides such as methylethylketone peroxide. For rapid curing it is usually required to heat the mixture. For operations at ambient temperature it is therefore customary to add an accelerator which has the effect of activating the catalyst at a lower temperature.
Accelerators suitable for use with organic peroxides are cobalt derivatives and combinations based on such derivatives. Examples of resin catalysts and accelerators are to found in technical manuals and literature.
As polyester resins containing effective proportions of catalyst hav a limited storage life it is preferable to add the catalyst to the resin immediately prior to use. It is however in order to add the accelerator to the uncatalysed polyester resin and such "pre-accelerated" resins have a storage life at room temperature.
Thus the present invention can employ a pre-accelerated polyester resin which is admixed with a catalyst immediately prior to introduction into the mould with the slate particles or the catalyst can be introduced separately into the mould for mixing with the pre-accelerated resin and slate particles to effect the curing operation.
Example of a pre-accelerated resin for use in the invention is that known under the Trade Name Polymaster 2946TAC LSE as manufactured by Warwick Chemical Limited. A suitable catalyst for this resin is methylethylkeketone peroxide supplied by the same manufacturer.
The roofing tiles can be formed with a gloss or a matt finish. During the setting period and while the resin is still viscous the slate particles tend to gravitate to the bottom of the mould and this is governed by the amount of resin introduced. A matt finish requires a smaller amount of resin than a gloss finish.
As mentioned originally, instead of forming tiles in individual moulds, a sheet or layer of the mixture can be allowed to set and the sheet then cut into tiles of a required shape and size.
Instead of forming flat tiles or sheets it is possible to mould curved or other shapes and if required a pattern or design can be included in the moulded product.
A slate roofing tile according to the invention is lighter in weight than a natural slate tile of the same dimensions and is shatterproof by virtue of the addition of the reinforcement. The tile of the invention can be made in any required size and shape and is not restricted to a planar configuration. Nails or the like can be driven through the tile for fixing in position or the tile can be formed with holes therein to receive fixing pins or the like. The tile of the invention retains the colour of natural slate and does not fade with time. If required the natural colour of the slate can be modified or changed by adding a colouring agent to the mixture in the mould. The tile can have a gloss or matt finish. A further advantage is that the invention can be used for repair work.For example, a broken or damaged tile can be repaired by patching with the slate/resin mixture which on setting will bond itself in place.
The manufacture and production of slate roofing tiles and other slate containing products according to the invention will lead to substantial savings in cost as compared to natural slate products and has the advantage of using the waste and tailings at quarries.
Whilst particular reference is made to roofing tiles it will be appreciated that the invention is applicable to other slate products such as floor tiles, paving blocks and slate products and articles in general.
Thus another application of the invention can reside in the production of moulded articles which generally comprise fibreglass or the like impregnated with a resin. Examples of such articles are hulls for small boats and panels or bodies for vehicles. Slate particles can be included in the production of these articles with the advantage of reducing the resin content thereof at a substantial saving in cost and without reducing the strength or quality of the finished article.
In addition to the previously mentioned reinforcements it is possible to utilise cloth such as hessian or jute into the mixture to absorb impact shocks. Clearly other materials can also be suitable as reinforcement.
Finally, in the production of tiles or other articles on a continuous basis, the moulds can be formed in a conveyor belt. The moulds are filled with slate/resin mixture at or near one end of the forward run of the belt and the speed of the belt is such that the mixture has set and the moulded article ejected from its mould at the end of the forward run. On the return run the moulds can be washed and cleaned and treated with a release agent before again reaching the start af the forward run and a fresh charge of the slate/resin mixture.

Claims (10)

1. A method of forming a slate product comprising mixing slate particles as hereinbefore defined with a thermosetting resin and allowing the mixture to set into a desired shape and size.
2. A method of forming a slate product according to claim 1 which comprises introducing a reinforcement into the mixture.
3. A method according to claim 2 in which the reinforcement comprises a mat or a mesh.
4. A method according to any preceding claim including allowing the mixture to set in a vibratory mould.
5. A method according to claim 1 and substantially as hereinbefore described.
6. A slate product comprising slate particles bonded with a thermosetting resin into a unitary product of desired shape and size.
7. A slate product according to claim 6 including a reinforcement in the slate/resin mixture.
8. A slate product according to claim 7 in which the reinforcement comprises glass fibre or a plastics or metal mesh.
9. A slate product according to claim 6, 7 or 8 which comprises a roofing tile.
10. A slate product according to claim 6 substantially as hereinbefore described.
GB8003715A 1979-02-02 1980-02-04 Slate filled resin products Expired GB2041959B (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GB7903771 1979-02-02

Publications (2)

Publication Number Publication Date
GB2041959A true GB2041959A (en) 1980-09-17
GB2041959B GB2041959B (en) 1983-04-07

Family

ID=10502932

Family Applications (1)

Application Number Title Priority Date Filing Date
GB8003715A Expired GB2041959B (en) 1979-02-02 1980-02-04 Slate filled resin products

Country Status (1)

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GB (1) GB2041959B (en)

Cited By (18)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2526015A1 (en) * 1982-04-28 1983-11-04 Hueck Fa E MOLDED REPRODUCTION HAVING A SURFACE STRUCTURE SIMILAR TO THAT OF NATURAL SLATE
FR2530615A1 (en) * 1982-07-20 1984-01-27 Fidalgo Lopez B PROCESS FOR THE RECONSTITUTION OF ROCKS AND PARTICULARLY SLATE
GB2129002A (en) * 1982-09-13 1984-05-10 Brian Bennett Filled thermosetting resin compositions
GB2135324A (en) * 1983-02-25 1984-08-30 Diasol Sarl Process for manufacture of slates from waste slate
GB2157704A (en) * 1984-02-14 1985-10-30 E H Bradley Building Products Building materials; artificial slate
GB2202544A (en) * 1987-03-11 1988-09-28 John Murdoch Thornton Masson Surface treatment material particularly useful for tiled roofs
GR880100462A (en) * 1988-07-11 1990-06-27 Tampakakis Stefanos 6817503 Reinforced resin powder mixture beam
EP0400244A1 (en) * 1987-12-01 1990-12-05 Societe Des Schistes Bleus Du Cotentin Covering elements and processes and devices for manufacturing same
GB2233640A (en) * 1989-01-11 1991-01-16 Frank Brendan Devlin Mineral composition
GB2197673B (en) * 1986-11-12 1991-04-03 Harris Frederick Brian Oatway Fabricated building products
WO1994004774A1 (en) * 1992-08-11 1994-03-03 Meirion Gribble Roofing tiles
WO1996034160A1 (en) * 1995-04-24 1996-10-31 Owens Corning Shingle of resinous material and filler
WO1996034162A1 (en) * 1995-04-24 1996-10-31 Owens Corning A roof containing resinous material and filler
US6021611A (en) * 1995-04-24 2000-02-08 Wells; James R. Shingle having ribs and a cavity on its underside
WO2003011544A1 (en) * 2001-07-27 2003-02-13 Ogden Industries Limited A method of forming a tile, a tile, a roofing structure and a mould
US8136322B2 (en) 2009-08-25 2012-03-20 Tamko Building Products, Inc. Composite shingle
US20120178851A1 (en) * 2009-07-21 2012-07-12 Cupa Innovacion, S.L.U. Resin with high heat transfer
EP3798198A1 (en) 2019-07-26 2021-03-31 Empresa das Lousas de Valongo, SA Composite material, method for obtaining the same and articles thereof

Cited By (23)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2526015A1 (en) * 1982-04-28 1983-11-04 Hueck Fa E MOLDED REPRODUCTION HAVING A SURFACE STRUCTURE SIMILAR TO THAT OF NATURAL SLATE
FR2530615A1 (en) * 1982-07-20 1984-01-27 Fidalgo Lopez B PROCESS FOR THE RECONSTITUTION OF ROCKS AND PARTICULARLY SLATE
GB2124201A (en) * 1982-07-20 1984-02-15 Fidalgo Lopez B Process for the reconstitution of slates
GB2129002A (en) * 1982-09-13 1984-05-10 Brian Bennett Filled thermosetting resin compositions
GB2135324A (en) * 1983-02-25 1984-08-30 Diasol Sarl Process for manufacture of slates from waste slate
FR2541673A1 (en) * 1983-02-25 1984-08-31 Diasol Sarl PROCESS FOR MANUFACTURING SLATE AND IMPROVED COVERING ELEMENTS
GB2157704A (en) * 1984-02-14 1985-10-30 E H Bradley Building Products Building materials; artificial slate
GB2197673B (en) * 1986-11-12 1991-04-03 Harris Frederick Brian Oatway Fabricated building products
GB2202544A (en) * 1987-03-11 1988-09-28 John Murdoch Thornton Masson Surface treatment material particularly useful for tiled roofs
EP0400244A1 (en) * 1987-12-01 1990-12-05 Societe Des Schistes Bleus Du Cotentin Covering elements and processes and devices for manufacturing same
GR880100462A (en) * 1988-07-11 1990-06-27 Tampakakis Stefanos 6817503 Reinforced resin powder mixture beam
GB2233640A (en) * 1989-01-11 1991-01-16 Frank Brendan Devlin Mineral composition
WO1994004774A1 (en) * 1992-08-11 1994-03-03 Meirion Gribble Roofing tiles
WO1996034160A1 (en) * 1995-04-24 1996-10-31 Owens Corning Shingle of resinous material and filler
WO1996034162A1 (en) * 1995-04-24 1996-10-31 Owens Corning A roof containing resinous material and filler
US5615523A (en) * 1995-04-24 1997-04-01 Owens-Corning Fiberglas Technology, Inc. Roof having resinous shingles
US6021611A (en) * 1995-04-24 2000-02-08 Wells; James R. Shingle having ribs and a cavity on its underside
US6112492A (en) * 1995-04-24 2000-09-05 Owens Corning Fiberglas Technology, Inc. Shingle having ribs and cavity on its underside
WO2003011544A1 (en) * 2001-07-27 2003-02-13 Ogden Industries Limited A method of forming a tile, a tile, a roofing structure and a mould
US20120178851A1 (en) * 2009-07-21 2012-07-12 Cupa Innovacion, S.L.U. Resin with high heat transfer
EP2457971A4 (en) * 2009-07-21 2015-10-28 Cupa Innovación S L U Resin with high heat transfer
US8136322B2 (en) 2009-08-25 2012-03-20 Tamko Building Products, Inc. Composite shingle
EP3798198A1 (en) 2019-07-26 2021-03-31 Empresa das Lousas de Valongo, SA Composite material, method for obtaining the same and articles thereof

Also Published As

Publication number Publication date
GB2041959B (en) 1983-04-07

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Legal Events

Date Code Title Description
732 Registration of transactions, instruments or events in the register (sect. 32/1977)
PCNP Patent ceased through non-payment of renewal fee

Effective date: 19970204