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WO2004039564A1 - Method for manufacturing elements from powders and granules - Google Patents

Method for manufacturing elements from powders and granules Download PDF

Info

Publication number
WO2004039564A1
WO2004039564A1 PCT/IB2003/004870 IB0304870W WO2004039564A1 WO 2004039564 A1 WO2004039564 A1 WO 2004039564A1 IB 0304870 W IB0304870 W IB 0304870W WO 2004039564 A1 WO2004039564 A1 WO 2004039564A1
Authority
WO
WIPO (PCT)
Prior art keywords
provides
powders
mixture
press
granules
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/IB2003/004870
Other languages
French (fr)
Inventor
Max Canti
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.)
ECO NEW TECHNOLOGY LLC
Original Assignee
ECO NEW TECHNOLOGY LLC
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 ECO NEW TECHNOLOGY LLC filed Critical ECO NEW TECHNOLOGY LLC
Priority to AU2003276502A priority Critical patent/AU2003276502A1/en
Publication of WO2004039564A1 publication Critical patent/WO2004039564A1/en
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

Links

Classifications

    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • B29K2105/16—Fillers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/10—Building elements, e.g. bricks, blocks, tiles, panels, posts, beams
    • B29L2031/104—Tiles
    • 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

  • the present invention relates to the production of coverings, flooring or furnishing material and particularly it refers to a procedure for manufacturing elements from powders and/or granules by agglomeration of said powders and/or powder granules obtained from anhydrous mud, material and waste products deriving from the working of stones, marble, granite, gres, biological materials such as shells, hulls and similar or other, pure or mixed with or without addition of flours or organic fibers or recycled plastic or rubbery material granules.
  • a monobloc is obtained by compacting and consolidating the agglomerate and afterwards it must be cut, smoothed and worked for obtaining the desired elements.
  • the main drawback of said known methods consists in that it is necessary to harden and to consolidate the agglomerate during the phase of high pressure pressing and heating, this involving a low productivity because of the too long stay in the expensive press.
  • An object of the present invention is to propose a method for manufacturing elements, such as tiles or slabs, by agglomeration of powders, with high productivity. Further object is to propose a method requiring the use of presses having reduced size and cost.
  • Another object of the present invention is to propose a method allowing the production of tiles or slabs which have small dimensions as well and thus which can be easily moved and manipulated in the following working and finishing stations.
  • the method object of the present invention for manufacturing elements from powders and granules by agglomeration of powders basically provides :
  • the powders derive from anhydrous mud i.e. dried mud and/or waste granulate products, which are obtained by working stones, marbles, granites, gres or other. Dyes, flours or organic fibers, plastic or rubbery material beads, rubber or recycled plastic material granules can be added to the mixture, besides the resins, in order to provide the moulded elements with flexibility and soundproofing characteristics for instance.
  • anhydrous mud i.e. dried mud and/or waste granulate products, which are obtained by working stones, marbles, granites, gres or other.
  • Dyes, flours or organic fibers, plastic or rubbery material beads, rubber or recycled plastic material granules can be added to the mixture, besides the resins, in order to provide the moulded elements with flexibility and soundproofing characteristics for instance.
  • each moulded element is inserted into a low- pressure continuous press, for instance a belt press, having a predefined feed speed, from 2 to 20 meters per minute, and a heating temperature, from 80° C to 300° C.
  • the feed speed is related to the press length and to the time needed for hardening and consolidation; the heating temperature and the pressure are predefined by the reaction time of the used resins.
  • a belt press with a length of 18 meters in order to allow a resin reaction time of 3 minutes at 100°C, will move the elements at a speed of around 6 m/minute. It is also provided that, in alternative or in addition to the speed adjustment, the temperature can also be regulated to supply the prefixed amount of thermal energy for hardening the resin.
  • the method further provides to uniformly pour the mixture into the mould through a vibrating dosing hopper, to automatically extract each element moulded by the high-pressure press and to insert the latter into the continuous low-pressure press.
  • the high-pressure press is constituted, for instance, by a moulding belt, of known type and not shown, to which a plurality of shaped moulds are constrained, in which the mixture is compressed by one or more couples of punches/counterpunches.
  • the shaped punches allow obtaining elements having different shapes and dimensions, which can be provided, in case, with decorations, relieves, low relieves, incisions, generally ornamental motives in surface.
  • the method of the present invention even if it guarantees a high production, allows also to use high pressure presses having reduced dimensions, thus contained cost, allowing to manufacture at the same time moulded elements, such as tiles or slabs, which have small dimensions and thus which can be comfortablyand easily moved and worked.
  • the main advantage of the present invention is to provide a method for manufacturing tiles or slabs by agglomeration of powders with high productivity and requiring presses having reduced size and cost.
  • Another advantage of the present invention is to provide a method allowing the production of tiles or slabs which have small dimensions and thus which can be easily moved and manipulated in the following working and finishing stations.

Landscapes

  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Materials Engineering (AREA)
  • Structural Engineering (AREA)
  • Organic Chemistry (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)

Abstract

A method for manufacturing elements from powders and/or granules provides to: - to mix said powders and/or granules with resins until to obtain an almost homogeneous 5 mixture; - to pour said mixture into at least a forming mould; - to compact and to mould said mixture, by means of a high-pressure press, in order to obtain a moulded and compact element; - to heat said moulded element for hardening the resins and consolidating said element.

Description

METHOD FOR MANUFACTURING ELEMENTS FROM POWDERS AND GRANULES
TECHNICAL FIELD
The present invention relates to the production of coverings, flooring or furnishing material and particularly it refers to a procedure for manufacturing elements from powders and/or granules by agglomeration of said powders and/or powder granules obtained from anhydrous mud, material and waste products deriving from the working of stones, marble, granite, gres, biological materials such as shells, hulls and similar or other, pure or mixed with or without addition of flours or organic fibers or recycled plastic or rubbery material granules.
BACKGROUND ART
There are known method for manufacturing slabs or synthetic stones from agglomerates of stone powders and different minerals, suitably mixed with resins and subjected to the simultaneous action of high pressures and temperatures by means of heated presses, fit for forming and hardening said slabs or stones.
A monobloc is obtained by compacting and consolidating the agglomerate and afterwards it must be cut, smoothed and worked for obtaining the desired elements.
The main drawback of said known methods consists in that it is necessary to harden and to consolidate the agglomerate during the phase of high pressure pressing and heating, this involving a low productivity because of the too long stay in the expensive press.
Other drawback consists in that said methods allow manufacturing rough slabs of large dimensions, which must be manipulated, moved by suitable expensive apparatuses and which then must be cut and smoothed, with consequent long times of working and huge quantities of produced powders.
DISCLOSURE OF THE INVENTION
An object of the present invention is to propose a method for manufacturing elements, such as tiles or slabs, by agglomeration of powders, with high productivity. Further object is to propose a method requiring the use of presses having reduced size and cost.
Other object of the present invention is to propose a method allowing the production of tiles or slabs which have small dimensions as well and thus which can be easily moved and manipulated in the following working and finishing stations.
BEST MODE OF CARRYING OUT THE INVENTION
The method object of the present invention for manufacturing elements from powders and granules by agglomeration of powders basically provides :
to mix powders with mono or bi-component resins, in case thermosetting, till to obtain an almost homogeneous mixture having a percentage by volume of powders and/or of granules ranging from 50% and 99% of the total volume; - to uniformly pour the obtained mixture into a press mould; to compact and mould the mixture at high pressure, from 100 to 550 Kg/cm2, till to obtain a moulded and compact element; to heat the moulded element for hardening the resins and consolidating said element.
The powders derive from anhydrous mud i.e. dried mud and/or waste granulate products, which are obtained by working stones, marbles, granites, gres or other. Dyes, flours or organic fibers, plastic or rubbery material beads, rubber or recycled plastic material granules can be added to the mixture, besides the resins, in order to provide the moulded elements with flexibility and soundproofing characteristics for instance.
It is provided that the resin hardening and the consolidation of each element can be obtained by heating at low pressure, from 2 to 20 Kg/cm2, in order to maintain the compactness of the moulded element during the hardening. Preferably, each moulded element is inserted into a low- pressure continuous press, for instance a belt press, having a predefined feed speed, from 2 to 20 meters per minute, and a heating temperature, from 80° C to 300° C. The feed speed is related to the press length and to the time needed for hardening and consolidation; the heating temperature and the pressure are predefined by the reaction time of the used resins. For instance, a belt press with a length of 18 meters in order to allow a resin reaction time of 3 minutes at 100°C, will move the elements at a speed of around 6 m/minute. It is also provided that, in alternative or in addition to the speed adjustment, the temperature can also be regulated to supply the prefixed amount of thermal energy for hardening the resin.
The method further provides to uniformly pour the mixture into the mould through a vibrating dosing hopper, to automatically extract each element moulded by the high-pressure press and to insert the latter into the continuous low-pressure press.
The high-pressure press is constituted, for instance, by a moulding belt, of known type and not shown, to which a plurality of shaped moulds are constrained, in which the mixture is compressed by one or more couples of punches/counterpunches. The shaped punches allow obtaining elements having different shapes and dimensions, which can be provided, in case, with decorations, relieves, low relieves, incisions, generally ornamental motives in surface.
It is important to underline that the method of the present invention even if it guarantees a high production, allows also to use high pressure presses having reduced dimensions, thus contained cost, allowing to manufacture at the same time moulded elements, such as tiles or slabs, which have small dimensions and thus which can be comfortablyand easily moved and worked.
The main advantage of the present invention is to provide a method for manufacturing tiles or slabs by agglomeration of powders with high productivity and requiring presses having reduced size and cost.
Other advantage of the present invention is to provide a method allowing the production of tiles or slabs which have small dimensions and thus which can be easily moved and manipulated in the following working and finishing stations.

Claims

1) Method for manufacturing elements from powders and/or granules characterized in that provides to: - to mix said powders and/or granules with at least a resin until to obtain an almost homogeneous mixture; to pour said mixture into at least a forming mould; to compact and to mould said mixture by means of a high-pressure press, in order to obtain a moulded and compact element; - to heat said moulded element for hardening the resin and consolidating the element.
2) Method according to claim 1 characterized in that provides to mix powders of anhydrous mud and/or of waste granulate products which are obtained by working stones, marble, granite, gres or other.
3) Method according to claim 1 characterized in that provides to mix mono-component, bi- component or thermosetting resins.
4) Procedure according to claim 1 characterized in that provides to mix dyes, flours or fibers, plastic or rubbery materials with said powders.
5) Method according to claim 1 characterized in that provides to heat at low pressure each element for hardening the resins and the element consolidation.
6) Method according to claim 5 characterized in that provides to obtain the low pressure heating by means of a low pressure continuous press, with predefined feed speed and heating temperature.
7) Method according to claim 1 characterized in that provides to uniformly pour the mixture into the mould by means of a vibrating dosing hopper.
8) Method according to claim 6 characterized in that provides to transfer automatically each element moulded by the high-pressure press to the low-pressure continuous press.
9) Method according to claim 1 characterized in that provides to pour the mixture into at least a shaped mould of the press in order to obtain elements having different shapes and dimensions and/or provided with decorations, relieves, ornamental motives in surface.
10) Method according to any of the preceding claims characterized in that the mixture includes a percentage by volume of powders and/or granules ranging from 50% to 99%.
11) Method according to any of the preceding claims characterized in that the compacting and moulding are carried out at a pressure ranging from 100 to 550 Kg/cm2.
12) Method according to claim 5 characterized in that provides to heat each element at low pressure and at a pressure from 2 to 20 Kg/cm2.
13) Method according to claim 6 characterized in that provides to move the elements along the low pressure continuous press at a speed from 2 to 20 meters per minute and at a temperature from 80° C to 300° C.
14) Method according to claim 13 characterized in that provides to regulate at least one between transit speed and temperature of elements along the low pressure continuous press to provide each element with the prefixed quantity of thermal energy for hardening the respective resin.
PCT/IB2003/004870 2002-10-31 2003-10-31 Method for manufacturing elements from powders and granules Ceased WO2004039564A1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
AU2003276502A AU2003276502A1 (en) 2002-10-31 2003-10-31 Method for manufacturing elements from powders and granules

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
ITBO2002A000692 2002-10-31
IT2002BO000692 ITBO20020692A1 (en) 2002-10-31 2002-10-31 PROCEDURE FOR MAKING ELEMENTS STARTING FROM POWDERS AND GRANULES.

Publications (1)

Publication Number Publication Date
WO2004039564A1 true WO2004039564A1 (en) 2004-05-13

Family

ID=11440400

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/IB2003/004870 Ceased WO2004039564A1 (en) 2002-10-31 2003-10-31 Method for manufacturing elements from powders and granules

Country Status (3)

Country Link
AU (1) AU2003276502A1 (en)
IT (1) ITBO20020692A1 (en)
WO (1) WO2004039564A1 (en)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1980543A3 (en) * 2007-04-12 2013-01-02 Aros S.r.l. Method for consolidating blocks or slabs made of a building material

Citations (13)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB995148A (en) * 1961-04-20 1965-06-16 I S Kahler & Co Process for the production of rigid fibrous ceiling and wall-plates
GB1127460A (en) * 1965-11-17 1968-09-18 Koppers Co Inc Process for manufacturing tiles
FR2096997A1 (en) * 1970-07-24 1972-03-03 Sefaplac Resin bound moulding prodn - esp imitation roofing slates using automatically charged consolidated and stripped flexible moulds
US3670060A (en) * 1968-12-10 1972-06-13 Medil Spa A method for manufacturing artificial marble
US3709650A (en) * 1970-11-05 1973-01-09 Electrohome Ltd Press for use in the molding of parts
DE3334396A1 (en) * 1983-09-23 1985-04-11 Mast, geb. Kaschub, Anita, 7580 Bühl Process for producing synthetic paving stone slabs
GB2231881A (en) * 1989-04-08 1990-11-28 Glasdon Manufacturing Limited Moulded articles of resin-bonded stone particles
WO1992010349A1 (en) * 1990-12-12 1992-06-25 Drazil, Jaromir, Vaclav A process and an apparatus for manufacturing a moulded article and a product made by the process
CH680377A5 (en) * 1990-05-28 1992-08-14 Helmut Hoedt
US5388979A (en) * 1989-09-08 1995-02-14 Agrifibre Developments Limited Mold and press assembly for press molding articles
WO1995013178A1 (en) * 1993-11-10 1995-05-18 Ebara Shoji Kabushiki Kaisha Method of and apparatus for manufacturing products of resin concrete, and formwork
EP0786325A1 (en) * 1996-01-29 1997-07-30 TONCELLI, Marcello Method and apparatus for the production of slabs of granulated stone materials and/or sands bound with a hardenable resin
EP1027970A2 (en) * 1999-02-09 2000-08-16 United States Gypsum Company Method of manufacture for textured surface panels and panel products made therefrom

Patent Citations (13)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB995148A (en) * 1961-04-20 1965-06-16 I S Kahler & Co Process for the production of rigid fibrous ceiling and wall-plates
GB1127460A (en) * 1965-11-17 1968-09-18 Koppers Co Inc Process for manufacturing tiles
US3670060A (en) * 1968-12-10 1972-06-13 Medil Spa A method for manufacturing artificial marble
FR2096997A1 (en) * 1970-07-24 1972-03-03 Sefaplac Resin bound moulding prodn - esp imitation roofing slates using automatically charged consolidated and stripped flexible moulds
US3709650A (en) * 1970-11-05 1973-01-09 Electrohome Ltd Press for use in the molding of parts
DE3334396A1 (en) * 1983-09-23 1985-04-11 Mast, geb. Kaschub, Anita, 7580 Bühl Process for producing synthetic paving stone slabs
GB2231881A (en) * 1989-04-08 1990-11-28 Glasdon Manufacturing Limited Moulded articles of resin-bonded stone particles
US5388979A (en) * 1989-09-08 1995-02-14 Agrifibre Developments Limited Mold and press assembly for press molding articles
CH680377A5 (en) * 1990-05-28 1992-08-14 Helmut Hoedt
WO1992010349A1 (en) * 1990-12-12 1992-06-25 Drazil, Jaromir, Vaclav A process and an apparatus for manufacturing a moulded article and a product made by the process
WO1995013178A1 (en) * 1993-11-10 1995-05-18 Ebara Shoji Kabushiki Kaisha Method of and apparatus for manufacturing products of resin concrete, and formwork
EP0786325A1 (en) * 1996-01-29 1997-07-30 TONCELLI, Marcello Method and apparatus for the production of slabs of granulated stone materials and/or sands bound with a hardenable resin
EP1027970A2 (en) * 1999-02-09 2000-08-16 United States Gypsum Company Method of manufacture for textured surface panels and panel products made therefrom

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1980543A3 (en) * 2007-04-12 2013-01-02 Aros S.r.l. Method for consolidating blocks or slabs made of a building material

Also Published As

Publication number Publication date
AU2003276502A1 (en) 2004-05-25
ITBO20020692A0 (en) 2002-10-31
ITBO20020692A1 (en) 2004-05-01

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