GB2041959A - Slate-filled resin products - Google Patents
Slate-filled resin products Download PDFInfo
- 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
Links
- 239000010454 slate Substances 0.000 title claims abstract description 57
- 229920005989 resin Polymers 0.000 title claims abstract description 36
- 239000011347 resin Substances 0.000 title claims abstract description 36
- 239000000203 mixture Substances 0.000 claims abstract description 30
- 239000002245 particle Substances 0.000 claims abstract description 23
- 230000002787 reinforcement Effects 0.000 claims abstract description 15
- 229920001187 thermosetting polymer Polymers 0.000 claims abstract description 10
- 239000003365 glass fiber Substances 0.000 claims abstract description 3
- 239000004033 plastic Substances 0.000 claims abstract description 3
- 229920003023 plastic Polymers 0.000 claims abstract description 3
- 238000000034 method Methods 0.000 claims description 10
- 239000002184 metal Substances 0.000 claims description 2
- 229910052751 metal Inorganic materials 0.000 claims description 2
- 239000000843 powder Substances 0.000 abstract description 3
- 229920000728 polyester Polymers 0.000 abstract 1
- 239000003054 catalyst Substances 0.000 description 11
- 238000004519 manufacturing process Methods 0.000 description 7
- 229920001225 polyester resin Polymers 0.000 description 5
- 239000004645 polyester resin Substances 0.000 description 5
- 238000000465 moulding Methods 0.000 description 4
- 239000003795 chemical substances by application Substances 0.000 description 3
- PPBRXRYQALVLMV-UHFFFAOYSA-N Styrene Chemical group C=CC1=CC=CC=C1 PPBRXRYQALVLMV-UHFFFAOYSA-N 0.000 description 2
- 239000000428 dust Substances 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 238000002474 experimental method Methods 0.000 description 2
- 239000011152 fibreglass Substances 0.000 description 2
- 150000001451 organic peroxides Chemical class 0.000 description 2
- 230000035939 shock Effects 0.000 description 2
- 238000003860 storage Methods 0.000 description 2
- WFUGQJXVXHBTEM-UHFFFAOYSA-N 2-hydroperoxy-2-(2-hydroperoxybutan-2-ylperoxy)butane Chemical compound CCC(C)(OO)OOC(C)(CC)OO WFUGQJXVXHBTEM-UHFFFAOYSA-N 0.000 description 1
- 240000000491 Corchorus aestuans Species 0.000 description 1
- 235000011777 Corchorus aestuans Nutrition 0.000 description 1
- 235000010862 Corchorus capsularis Nutrition 0.000 description 1
- 239000004677 Nylon Substances 0.000 description 1
- 230000003213 activating effect Effects 0.000 description 1
- 239000007767 bonding agent Substances 0.000 description 1
- 150000001868 cobalt Chemical class 0.000 description 1
- 238000004040 coloring Methods 0.000 description 1
- 239000000805 composite resin Substances 0.000 description 1
- 229920006037 cross link polymer Polymers 0.000 description 1
- 238000009826 distribution Methods 0.000 description 1
- 239000004744 fabric Substances 0.000 description 1
- 239000012634 fragment Substances 0.000 description 1
- 239000008187 granular material Substances 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 229920001778 nylon Polymers 0.000 description 1
- 150000002978 peroxides Chemical class 0.000 description 1
- 239000002002 slurry Substances 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 238000009827 uniform distribution Methods 0.000 description 1
- 239000002699 waste material Substances 0.000 description 1
Classifications
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
- E04D1/00—Roof covering by making use of tiles, slates, shingles, or other small roofing elements
- E04D1/12—Roofing elements shaped as plain tiles or shingles, i.e. with flat outer surface
- E04D1/22—Roofing 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
-
- 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
- C04B14/00—Use 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
- C04B14/02—Granular materials, e.g. microballoons
- C04B14/04—Silica-rich materials; Silicates
- C04B14/10—Clay
- C04B14/108—Shale, slate
-
- 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
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K3/00—Use of inorganic substances as compounding ingredients
- C08K3/34—Silicon-containing compounds
Landscapes
- 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.
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)
| Country | Link |
|---|---|
| GB (1) | GB2041959B (en) |
Cited By (18)
| 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 |
-
1980
- 1980-02-04 GB GB8003715A patent/GB2041959B/en not_active Expired
Cited By (23)
| 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 |