DE3147753A1 - Process and production mould for producing boards, and boards produced by the process and in the mould - Google Patents

Abstract

The invention relates to a process and to a mould for producing boards having a decorative and/or wear-resistant surface, solids being embedded in a hardened casting compound, and to boards produced according to this process. The invention is characterised in that one board is produced in each case in the mould in approximately the desired later board thickness, by first producing on at least one mould inside the later visible side as a base layer without solids and then casting the casting compound with the incorporated solids around this base layer. In the process according to the invention, the base layer is formed from a transparent and stabilised plastic by spraying or casting it in, whereupon the barrier layer, which then carries the solids and at the same time makes a joint with the casting compound, is fixed to the base layer. On the back of the board, a reinforcement is fixed in the casting compound, as well as, if appropriate, projecting anchoring or fixing elements. The back of the board can also be roughened by sprinkling with, for example, quartz sand. The boards produced by the process can be used as table leaves, for facade facing, for decorative covering of building surfaces, for floors or stair treads and the like.

Description

The invention relates to a method for producing

Plates, as well as a shape intended for carrying out the process and the panels made by this process in the mold.

It is known to produce panels from natural stone waste by the stone waste in disorderly sizes, and mainly in small pieces, poured into a block form and then potted with plastic or cement. After a hardening time of 3 days, the finished block is removed from the block mold and cut the block in layers into individual plates.

The surfaces of the plates obtained in this way are, like even normal natural stone slabs, first roughly sanded, then leveled, then sanded and finally finely polished. This work is very time-consuming and wage-intensive, especially since the filling still has to be done by hand. For the individual Work steps become expensive machines and devices as well as expensive additional material, namely putty and sanding blocks, needed, which affects the total manufacturing cost price increases. It is also known to make so-called sandstone slabs to produce, as a mass of concrete and filler material in an open-topped form poured in and on the upper side a determining the later structure of the visible side Pebble of pebbles is applied. These slabs are used for patios, c; walkways or Further processing of enclosures. For higher demands, these are sandstone slabs not usable.

The invention is based on the object of a method for Execution of the process suitable form as well as produced ah this process, also high requirements to create panels in their manufacture costly cutting and surface finishing work is no longer necessary.

According to the invention, the set object is achieved by the method, which by the features specified in the characterizing part of the flaupt claim With this process, panels of any size can already be produced can be produced much faster in the later plate thickness, with additional the laborious visual cutting and surface processing work is also dispensed with, which were previously required. The plate produced according to the invention can either already get the given size or the desired outline or by simple Cross cutting can be brought into the desired size or outline shape. It exists a solid Adhesion between the G # undschicht forming the visible side, the barrier layer and the embedded solid bodies, so that at least the result in the same properties as with real and conventionally manufactured Natural stone slabs. In addition to the considerable cost savings, there is also the special one The advantage of an extremely short duration of the procedure, since of course one already panel produced in the later panel thickness hardens much faster, as a block several times the plate thickness. In addition, this new process the influence of shrinkage during hardening is much weaker or not at all come into play, which is much more serious with the conventional block method affects. Since the process is carried out in several interlocking steps it is easily possible to make the base layer forming the visible side from another Manufacture of material that meets the requirements, and for the loss of solid bodies to use a cheaper material, since it only has the task of Connection to the base layer and the cohesion of the solid bodies.

Appropriately, the procedure according to the invention is as claimed 2 reveals. The later use properties can be determined for the first base layer determine exactly in advance. They are then also retained because the solid bodies are poured out can no longer influence it. Another, important advantage arises by the reinforcement of the back of the panel, through which the structural strength or the elasticity of the plate, which is brittle per se, is also increased for special applications can be.

Another, important variant of the process; is apparent from claim 3. The roughening or structuring on the back of the plate is special there Meaning where this plate is to be attached, e.g. on a facade.

As an alternative or in addition, a process step is also important, such as Claim 4 explains him. These measures are already used during manufacture the plate is provided with options for its subsequent attachment. With the after The traditional method cut panels had such anchors or Fasteners are introduced subsequently, which in turn was expensive because it is difficult to reduce the relatively high weight of the panels with as few anchoring or to transfer fasteners correctly to the supporting substrate.

When producing several small or plates of different sizes must be, it is rational to proceed according to claim 5. Dividing a large plate into several individual plates can be quickly converted by conventional means and easy to do, it should be noted that due to the barrier layer and the reinforcement is a particularly elastic and at the same time strong bond between the individual layers is achieved, so that when cross-cutting the risk of Breakouts or similar damage is avoided.

In practice, it has proven to be particularly expedient to use the inventive To carry out the method under the conditions set out in claim 6. There are for this neither special equipment, e.g. a drying oven, nor oversized storage space for the hardening of the plate is necessary, as each shape takes 20 to 30 minutes again-can be used to produce a new plate.

Another important idea of the invention is on a form for Implementation of the method according to the invention directed as it emerges from claim 7 shows. It is obvious that such a shape as compared to it significantly lower with the block shape normally used for such plates is, none the filling is subjected to special internal pressure, so that it can be made relatively easy and inexpensive. With little technical Such a casting mold can be complex for any desired plate size and shape produce. A casting mold with a certain frame height can also easily used to make a plate that has a smaller thickness; the Form only needs to be filled in a little less.

Another useful idea is contained in claim 8. With This step can be used to determine the subsequent surface quality of the base layer Predict the visible side or deliberately interpret it as it is for the respective Intended use is desirable. The base layer draws the surface structure the inside of the mold bottom surface exactly, the barrier layer preventing the solid bodies can penetrate to the actual visible side. This has for later use also the advantage that the base layer in a desired and is of uniform thickness.

The selection of materials highlighted in claim 9 is also important here, since with plastic molds the demolding of the finished plate is particularly easy can, and since a metal mold has a practically unlimited shelf life and possibly is equipped with a non-adhesive coating material that allows demoulding also relieved. It is also conceivable that the shape for producing the plate is similar to form a cake pan that can be dismantled.

The invention also relates to one of those mentioned at the outset Process in the above-explained #Form produced plate, which is through the in the characterizing part of claim 10 specified features.

This plate has a very abrasion-resistant and decorative side. The connection between the visible side and the cast solid bodies creates the barrier. The reinforcement on the back of the plate is through the potting compound adhered so that it is used for power transmission purposes will. Despite the multi-layer structure, the overall result is a monolithic structure, the finished panel being a desirable one despite its high structural strength Shows elasticity and is not as brittle as the conventionally manufactured panels.

Another important advantage is specified in claim 11. the The selected structuring of the visible side does not require any subsequent processing, but is already generated in the course of the process.

In practice, it has been shown to meet the requirements of claim 12 heed, because with this base layer thickness, which is adapted to the respective, desired performance characteristics can vary, the best results will be achieved will. A particularly decorative and at the same time abrasion-resistant base layer is in accordance with Claim 13 achieved, wherein the materials used are easy to process and are customary in the trade. The duration of the setting process can be increased by adding the hardener exactly before # - and tune in to the process flow, while the stabilizers ensure the durability of the base layer.

An important idea is also given in claim 14, because the light stabilization mentioned in it is an intended one even with solar radiation Suppress discoloration of the base layer.

Alternatively, the additive is also the feature specified in claim 15 important, especially when using the plate as a worktop for corrosive materials.

Another important training feature is explained in claim 16. 1 glass fiber mat can be particularly firmly between the base layer and the potting material. The particular advantage of a fiberglass mat but also lies in the fact that they are practical when soaking with a colorless synthetic resin becomes invisible and therefore its structural contours not from the outside. are recognizable although it does its job as a barrier and a connecting link perfectly. As a barrier layer, it not only has the effect that corners or tips of the Solid bodies cannot push into the base layer, but rather carry them also to a force or stress distribution over the entire plate, similar to a Reinforcement, at.

Another, expedient measure explains claim 17.

This potting compound not only has a relatively light specificity Weight, but is also particularly easy to process.

Another training feature mentions claim 18. This measure is mainly used for decorative purposes, as it may allow the structure through the arrangement of the solid bodies emphasizes, contrasts intensified or weakened.

The feature of claim 19 is also important. Such fabrics are customary. In connection with the potting compound, a particularly strong one results Reinforcement.

The sticking of the reinforcement in the potting compound is then special favored if the feature of claim 20 is given. This armoring equipment not only improves the integration into the potting compound, but also prevents that the casting compound dissolve the reinforcement and thus weaken its effect could.

In practice, a reinforcement like her has proven particularly successful from claim 21 can be seen.

If the created plate is e.g. on a facade or on a ceiling is to be attached, it is appropriate that its back is roughened. this can be achieved in a particularly simple manner by the measure specified in claim 22 The sprinkled quartz sand is embedded in the casting compound, however only at the top, so that there is a rough and large surface to cling to the slab, e.g. in concrete.

Finally, the design feature of claim 23 is also important, as this enables the plates to be attached in a particularly firm manner. Such Anchoring elements can be retaining nuts, for example, which are then inserted from the outside Fastening screws are screwed in or protruding claws, which are particularly can be firmly embedded in concrete.

The method according to the invention is described below with the aid of the drawing explained in more detail.

1 shows a perspective side view of one after the Process according to the invention produced plate, and FIG. 2 shows a cross section through a plate that is still in its production form after the production process has been completed.

From Fig. 1, a plate 1 can be seen, the visible side with 2 and the back of which is denoted by 3. The plate 1 is largely in use made of natural stone waste of any part size, from the visible side 2 can be seen from and result in the structuring of the plate 1.

On the visible side 2 of the plate 1 is a uniformly thick base layer 4 of a thickness between 0.5 and a maximum of 2 mm, which consists of an acrylic, an epoxy or polyester resin with additions of hardeners and light stabilizers, optionally amines. A barrier layer 5 is connected to the base layer 4, which is formed by a glass fiber mat. At this barrier is the real one. Main component of the plate adhered, namely one from the natural stone waste The solid body 7 formed by bonding compound 6.

This potting compound is in turn an acrylic, an epoxy or a polyester resin with hardening and stabilizing additives, which may be colored the structure of the solid body 7 to emphasize or weaken or

to create a high-contrast image on the visible side.

The coloring effect of the potting compound 6 is clear for example at 8 recognizable.

In the casting compound there is a reinforcement behind the solid bodies 9 embedded, which is formed by a glass roving fabric, expediently one silane-coated fabric with a basis weight of 900 g / m². This reinforcement 9 either forms the later plate back 3 or is slightly in the potting compound 6 embedded.

The plate can be of any size and shape. From a large plate can have several smaller panels of different sizes and with different outlines be cut out. The main advantage of these panels is their lightness, a certain elasticity and their frost resistance. In addition, the base layer can be acid-proof and designed to be particularly abrasion-resistant. Any post-processing can be omitted.

The plate 1 is produced according to FIG. 2 in a mold 11, which has a Mold bottom 17 and a frame running around here at the level of the later plate thickness 12 owns. The mold can be made of plastic or metal, e.g. made of polypropylene or polyethylene, or made of aluminum or steel. At her Training made of metal, it can be dismantled in the usual way.

The mold bottom 17 carries on its inside 13 the desired, later Profiling of the visible side of plate 1, i.e. it can either be polished, roughened or structured in any way. On this inside is the Base layer 4 applied by spraying or pouring on in a thickness of 0.5 to 2 mm, so that the structuring 13 of the inside is reproduced exactly.

On this thin plastic base layer, which is light stabilized, the barrier layer 5, namely a glass fiber mat, is placed so that there are no air bubbles can arise on the later visible side. In connection with the not yet hardened Plastic base layer 4, the fiberglass mat is absolutely transparent, so that their structure-related contours disappear.

This barrier layer 5 is then cut length and breakage, i. Pieces of natural stone, wood, possibly metal waste or plastic parts, piled up, depending on the board structure or the optical impression you get ~ want. Depending on the total panel thickness, these inlaid solid bodies can 7 have any size.

Then the joints between the solid bodies 7 with acrylic resin, Poured epoxy resin or polyester resin.

This plastic can also be colored if desired.

The potting compound 6 completely covers the solid body 7. On the The reinforcement 9, namely the glass roving fabric, is placed on the still liquid casting compound and pressed in if necessary. The resin layers are cured after 20 to 30 minutes and the plate can be removed from the mold 11.

In the event that the back of the plate 3 should be rough or non-slip, is sprinkled on the not yet set casting compound 7 quartz sand -18, the adheres and results in the desired roughness. Alternatively or additionally you can also anchoring elements 14 or fastening elements 15 in the still liquid Casting compound are introduced.

Make the plastic materials used. Sure the finished Plate is light and acid-proof and abrasion-resistant on its visible side that the plate is low in shrinkage and does not throw itself and that at least the same abrasion properties are given how tei the traditionally produced natural stone slabs. The procedure is preferably carried out at room temperature between .. -10 and 200 C, see above that no drying ovens or similar # facilities are required. The plates are.-is- can be used at temperatures of 70 C, as table-top.

panels, for facade covering, as coverings, for floors and as stairs.

Claims (23)

Method and production form for the production of panels and according to the process and panels produced in the mold Claims 1. Process for the production of panels with a decorative and / or wear-resistant surface, solid bodies embedded in a mold in a hardening potting compound be, d u r c h e k e n n -z e i c h n e t that in the form (11) a plate (1) manufactured in approximately the desired later plate thickness; is done by on at least one mold inside (13) first the later visible side (2) as one Base layer (4) produced without solids and then on the base layer () the inserted solid bodies (7) are encapsulated with the casting compound (6). 2. The method according to claim 1, d a d u r c h g e -k e n n z e i c h n e t that the base layer (4) is sprayed or poured that on the Base layer (4) a barrier layer (5) is applied and connected to it that The solid bodies (7), if necessary in layers, are placed on the barrier layer (5) be that thereupon the joints between the solid bodies (7) to complete Covering the solid body (7) are poured out, and that the not yet hardened Potting compound (6) reinforced on the rear side of the plate (3) facing away from the visible side (2) will. 3. The method according to claims 1 and 2, d a d u r c h g e k e n Nz e i c h n e t that the not yet hardened potting compound (6) on the back of the plate (3) is roughened or textured. 4. The method according to claims 1 to 3, d a d u r c h g e k e n n z e i c h n e t that anchors (14) in the casting compound (6) before hardening embedded or protruding fastening elements (15) are introduced. 5. The method according to claims 1 to 4, d a d u r c h g e k e n nz e i c h n e t that the plate (1) according to. their removal from the mold (11) transversely to the sight: Lten level in individual plates divided, preferably cut or sawn, is. 6. The method according to claims 1 to 5, d a d u r c h g e k e n It should be noted that the plate (1) takes approximately 20 to 30 minutes and at between 100C and 20 0C lying room temperature left to harden in the mold will. 7. For producing a plate according to the method according to the claims 1 to 6 certain form, which denotes that they are made of a base (17) and a non-running frame (12) at the level of the later Plate thickness. 8. Mold according to claim 7, d a d u r c h g e k e n n -z e i c h n e t that the inside (13) of the base (17) polished, matted or structured st. 9. Form according to claims 7 and 8, d a d u r c h g e k e n n z e i c h n e t that they are made of plastic, such as polyethylene or polypropylene or made of Metal, such as steel or aluminum, is made. 10. According to the method of claims 1 to 6 and in the form according to the claims 7 to 9 produced plate, in which the solid body natural or Artificial stones, wood, plastic or metal, alone or mixed together, possibly as waste, scrap or scrap parts are, d u r c h g e k e n n -z e i c h n e t that the later visible side; e (2) forming, transparent Base layer (4) made of plastic and provided with a transparent barrier layer is connected that the solid body (7) is placed on the barrier layer (5), in embedded in the potting compound (6) and connected via this to the barrier layer (5) are, and that the plate back (3) has a reinforcement (9), which is firmly adhering is applied or embedded. 11. Plate according to claim 10, d a d u r c n g e: k e n n -z e i c h n e t that the visible side (2) of the plastic base layer (4) according to the Tn.a # nfläche (13) of the mold side wall (17) is glossy, matt or structured. 12. Plate according to claims 10 and 11, d a d u r c h g e k e n n z t i c h n e t that the base layer each has a thickness between 0.5 and 2 mm. 13. Plate according to claims 10, 11 and 12, d a -d u r c h g> it is not noted that the base layer (+) is made of acrylic, epoxy or polyester resin consists, to which stabilizers and hardeners are added. 14. Plate according to claims 10 to 13, d a d u r c h g e k e n It is noted that the basic layer (4) contains light stabilizers, such as amines. 15. Plate according to claims 10 to 14, d a d u r c h g e k e n n z e i without t that the base layer (4) is acid-resistant and abrasion-resistant. 16. Plate according to claim 10, d a d u r c h g e k e n nz e i c h n e t that the barrier layer (5) at least one as a result of its impregnation with the plastic the base layer (4) is a contour-free, transparent glass fiber mat. 17. Plate according to claim 10, d a d u r c h g e k e n n -z e i c h n e t that the potting compound (5) made of acrylic, epoxy or polyester resin, if necessary with the addition of hardeners. 18. Plate according to claim 17, d a d u r c h g e k e n n -z e i c h n e t that the casting compound (5) is colored. 19. Plate according to claim 10, d a d u r c h g e k e n n -z e i c h n e t that the reinforcement (9) is a glass roving fabric. 20. Plate according to claim 19, d a d u r c h g e k e n n -z e i c h n e t that the reinforcement (9) is SLLAN coated. 21. Plate according to claims 19 and 20, d a d u r c h g e k e n It is noted that the reinforcement (9) has a weight per unit area of approximately 900 g / m2 owns. 22. Plate according to claims 10 to 21, d a d u r c h g e ic e n It is noted that on the back of the plate (3) it is scattered for roughening and adhered quartz sand (18) is located. 23. Plate according to claims 10 to 22, d a d u r c h g e k e n n z e i h n e t that there are anchors (14) or in the back of the plate (3) protruding fastening elements (15) are located.