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WO1992013809A1 - Moulage d'une pierre artificielle - Google Patents

Moulage d'une pierre artificielle Download PDF

Info

Publication number
WO1992013809A1
WO1992013809A1 PCT/GB1992/000175 GB9200175W WO9213809A1 WO 1992013809 A1 WO1992013809 A1 WO 1992013809A1 GB 9200175 W GB9200175 W GB 9200175W WO 9213809 A1 WO9213809 A1 WO 9213809A1
Authority
WO
WIPO (PCT)
Prior art keywords
mould
parts
blend
thixotropic
weight
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/GB1992/000175
Other languages
English (en)
Inventor
Brian Milton Smith
Christopher Cyril Smith
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.)
Recon Developments Ltd
Original Assignee
Recon Developments Ltd
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 Recon Developments Ltd filed Critical Recon Developments Ltd
Priority to GB9318046A priority Critical patent/GB2270921B/en
Publication of WO1992013809A1 publication Critical patent/WO1992013809A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

Links

Classifications

    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G18/00—Polymeric products of isocyanates or isothiocyanates
    • C08G18/06—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
    • C08G18/08—Processes
    • C08G18/0838—Manufacture of polymers in the presence of non-reactive compounds
    • 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
    • C04B26/16—Polyurethanes
    • 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
    • C08K3/01—Use of inorganic substances as compounding ingredients characterized by their specific function
    • C08K3/013—Fillers, pigments or reinforcing additives

Definitions

  • This invention relates to the moulding of artificial stone.
  • a method of producing a moulded body simulating a mineral stone material which comprises providing a first thixotropic prepolymer formulation comprising 0.5 to 1.5 parts by weight of a viscous polyol prepolymer containing a least 0.5 parts by weight of a paniculate mineral filler which is substantially non-porous and anhydrous; providing a second thixotropic prepolymer formulation comprising 0.5 to 1.5 parts by weight of a reactive viscous polyisocyanate containing at least 0.5 parts by weight of a paniculate mineral filler which is substantially non-porous and anhydrous, and which may be the same as the first-mentioned filler, or different thereto, blending said first and second thixotropic formulations together and allowing them to gel, introducing the gelled blend into a mould, allowing the blend to cure in said mould, and demoulding the resulting cured blend once the cure is substantially complete.
  • the respective mould parts may, for example, each comprise a formed sheet of plastics, such as polystyrene, which can enable a moulded body to be produced with an extremely smooth surface, but also with considerable sharpness of detail.
  • Plastics such as polystyrene
  • Articles of smooth artificial stone such as marble and onyx substitutes can be made from it with convincing reality with a surface complementary to that of the mould.
  • the interior surface of the mould inevitably begins to deteriorate, but it need not then be discarded; it can be used to mould further articles in artificial stone whose finish is not expected or required to be so smooth or shiny.
  • the mould may then complete its useful life after about a dozen uses but its materials and its process of manufacture are cheap enough to make this economic.
  • the resulting moulded body may be highly resistant to thermal shock and may be suitable for the moulding of aesthetic features in the home/hotels such as fire surrounds, lamp bases etc., in a range of luxury effects emulating e.g. marble and onyx.
  • the properties of the product also allow it to be used to manufacture a full range of bathroom and sanitary ware.
  • the afore-mentioned properties of the invention are superior to other cross-linked synthetic polymeric substances currently available for the stated purposes. Apart from aesthetics, the resulting body also has superior hardness, strength and can well exceed the ultimate hot and cold water cycle requirements.
  • the polyol prepolymer is generally an alkylene oxide adduct of a polyol (that is, a polyether polyol) or of a polyamine, which polyols typically have 4 to 8 carbon atoms (e.g. 1, 4-butane diol). It is typically a white liquid having a viscosity of 5000 to 15000 (preferably 10000 to 14000) centipoise at 25°C and a specific gravity of 1.5 to 1.6 (such as 1.53 to 1.57), also at 25°C.
  • the polyol formulation generally contains catalyst for the urethane-forming reaction with the polyisocyanate.
  • Such catalysts may be based on mercury, tin, bismuth or vanadium, optionally in combination with one or more tertiary amine.
  • the catalyst may be present in an amount of 0.05 to 5%, based on the weight of polyol.
  • An example of such a material is commercially available under the name Hyperlast 7853289.
  • the polyol formulation may contain a water-binding or desicating agent (that is, a material which absorbs unwanted water); an example of such a material is a molecular sieve, such as that available commercially under the name Sylosiv.
  • the filler may comprise stone dust, marble, chalk or lime, or granules of materials such as slate, alumina or pulverised fly ash. It is the filler powder that determines the type of stone that is simulated. For an onyx effect, for example, white alumina powder Al 2 O 3 is suitable.
  • a marbled effect can be obtained using pulverised fly ash, such as the material commercially available under the name Thermalite.
  • the polyisocyanate prepolymer is typically di (4-isocyanatophenyl) methane (MDI), an MDI prepolymer, or the like, the polyisocyanate may be the partial reaction product of a polyol and a polyisocyanate.
  • the polyisocyanate is typically a white liquid having a viscosity of 5000 to 15000 centipoise at 25°C and a specific gravity of 1.7 to 1.8 (such as about 1.73 to 1.75) also at 25°C.
  • the polyisocyanate typically has a functionality of 2.0 to 2.7, such as 2.1 to 2.3. An example of such a material is commercially available under the name Hyperlast 7855052.
  • the filler for the polyisocyanate may be substantially as described with reference to the polyol; it is preferred that a filler of the same nature should be used in the two prepolymer formulations.
  • the resulting moulding is preferably substantially foam-free (for which purpose, water is rigorously excluded from the blend).
  • the blend of the two thixotropic formulations be mixed with a pigment, which is mixed in such a way that the polymer curing takes place more rapidly than diffusion of the pigment into the polymer.
  • a veining effect simulating that of natural marble, may be attained.
  • the pigment may be solid or in the form of a paste or the like.
  • the pigment may be mixed with the whole batch of blended prepolymers. However, in a preferred embodiment, part of the batch may be separated off to be blended with the pigment to form a masterbatch; this masterbatch is then gently mixed with the remainder of the batch of blended prepolymers.
  • Stone filler was mixed with polyol (equal parts by weight) in a suitably sized container using an electric mixer, until an acceptable thixotropic dispersion was achieved.
  • the MDI was separately mixed with stonefiller (equal parts by weight), and then mixed with the first blend.
  • TiO 2 pigment was then blended, followed by a catalyst sufficiently to achieve an homogeneous mixture,- which was allowed to gel.

Landscapes

  • Chemical & Material Sciences (AREA)
  • Organic Chemistry (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Health & Medical Sciences (AREA)
  • Medicinal Chemistry (AREA)
  • Polymers & Plastics (AREA)
  • Structural Engineering (AREA)
  • Materials Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Polyurethanes Or Polyureas (AREA)
  • Compositions Of Macromolecular Compounds (AREA)

Abstract

On réalise le moulage par mélange de formulations à charge dense de prépolymères thixotropes de polyol et de polyisocyanate, respectivement, les formulations comportant une charge minérale anhydre et non poreuse, par gélification du mélange et ensuite par durcissement du matériau gélifié dans un moule à surface lisse. L'aspect veineux peut être obtenu grâce à l'addition d'un concentré pigmenté au gel avant l'introduction dans le moule.
PCT/GB1992/000175 1991-01-30 1992-01-30 Moulage d'une pierre artificielle Ceased WO1992013809A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
GB9318046A GB2270921B (en) 1991-01-30 1992-01-30 Moulding of artificial stone

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GB9102025.5 1991-01-30
GB919102025A GB9102025D0 (en) 1991-01-30 1991-01-30 Improvements relating to moulding of artificial stone

Publications (1)

Publication Number Publication Date
WO1992013809A1 true WO1992013809A1 (fr) 1992-08-20

Family

ID=10689255

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/GB1992/000175 Ceased WO1992013809A1 (fr) 1991-01-30 1992-01-30 Moulage d'une pierre artificielle

Country Status (3)

Country Link
AU (1) AU1196892A (fr)
GB (2) GB9102025D0 (fr)
WO (1) WO1992013809A1 (fr)

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0628580A1 (fr) * 1993-05-15 1994-12-14 Th. Goldschmidt AG Procédé de préparation de polymères contenant des groupes de polyuréthane et/ou de polyurée
AU657647B2 (en) * 1993-02-19 1995-03-16 Ralph Wilson Plastics Co. Varicolored articles with crystalline thermoplastic chips
ES2119624A1 (es) * 1995-03-16 1998-10-01 Perez Juan Lozano Procedimiento de fabricacion de lapidas funerarias.
US20110059319A1 (en) * 2007-10-11 2011-03-10 Tse Industries, Inc. Method for spray forming high modulus polyurethane structures

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2028015A1 (fr) * 1969-01-09 1970-10-02 Ici Ltd
BE855060A (nl) * 1977-05-26 1977-09-16 Scholten Honig Res B V Hardbare bindmiddelsamenstelling, hardbare mengsels van deze bindmiddelsamenstellingen met zand, en uit deze mengsels gevormde
US4279799A (en) * 1979-10-31 1981-07-21 The Goodyear Tire & Rubber Company Loaded polyurethane articles
GB2083484A (en) * 1980-09-10 1982-03-24 Texaco Development Corp Reinforced Reaction Injection Molded Elastomers

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2028015A1 (fr) * 1969-01-09 1970-10-02 Ici Ltd
BE855060A (nl) * 1977-05-26 1977-09-16 Scholten Honig Res B V Hardbare bindmiddelsamenstelling, hardbare mengsels van deze bindmiddelsamenstellingen met zand, en uit deze mengsels gevormde
US4279799A (en) * 1979-10-31 1981-07-21 The Goodyear Tire & Rubber Company Loaded polyurethane articles
GB2083484A (en) * 1980-09-10 1982-03-24 Texaco Development Corp Reinforced Reaction Injection Molded Elastomers

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
AU657647B2 (en) * 1993-02-19 1995-03-16 Ralph Wilson Plastics Co. Varicolored articles with crystalline thermoplastic chips
EP0628580A1 (fr) * 1993-05-15 1994-12-14 Th. Goldschmidt AG Procédé de préparation de polymères contenant des groupes de polyuréthane et/ou de polyurée
ES2119624A1 (es) * 1995-03-16 1998-10-01 Perez Juan Lozano Procedimiento de fabricacion de lapidas funerarias.
US20110059319A1 (en) * 2007-10-11 2011-03-10 Tse Industries, Inc. Method for spray forming high modulus polyurethane structures

Also Published As

Publication number Publication date
AU1196892A (en) 1992-09-07
GB9318046D0 (en) 1993-12-22
GB2270921B (en) 1995-07-05
GB2270921A (en) 1994-03-30
GB9102025D0 (en) 1991-03-13

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