RU2179536C1 - Chemical industry, more particularly manufacture of decorative glass slabs - Google Patents

Abstract

FIELD: chemical industry, more particularly manufacture of decorative glass slabs. SUBSTANCE: mixture of constructional layer components is applied onto decorative layer in amount which is required for manufacturing slabs of preset thickness and with additives that allow for layer to be hardened at ambient temperature and desired physico-mechanical characteristics in slab. EFFECT: lower manufacturing cost of slabs due to reduced consumption of thermal energy in manufacturing slabs. 4 cl, 7 dwg

Description

 The invention relates to the production of decorative structural materials for interior and exterior decoration of buildings, industrial and residential areas, healthcare facilities, etc.

 The internal and external cladding of buildings is usually carried out with natural and artificial decorative materials, most often it is marble and granite, as well as various types of ceramic tiles. The structural materials used must be not only decorative, but also functional and possess the following properties: durability, moisture resistance, be chemically neutral, heat insulating, wear-resistant, and at the same time, their production and installation should be inexpensive. Such a material that successfully replaces the above-mentioned natural ones when decorative facing of surfaces is glass silica fume. It meets all the standards of natural materials and their requirements. This material has all those uses, like natural stone, while it is not exposed to acids and alkalis, does not absorb odors, any deposits are easily washed off its surface, and its radiation background is zero. The front side of this material is a vitrified, fire-polished, matte or rough surface of almost any color with a diverse range of shades and patterns. This material is layered. It consists of a decorative layer that carries the above-mentioned advantages, and a structural layer with a reverse sand surface, which provides it with good adhesion to concrete surfaces of buildings by means of a conventional cement-sand mortar (A.S. 546569, 1974).

 Known decorative structural material for the manufacture of fiberglass plates and the method of its manufacture (US Pat. US 5792524 from 1998).

 The method includes preparing compositions of components of the decorative and structural layers, feeding the components to the bottom of the mold, followed by heat treatment and cooling. Due to the fact that various components are introduced into the composition of the structural layer of the material, affecting its structure, such a material performs decorative functions combined with others. For example, it can be both decorative and heat-protective, decorative and roofing, and decorative and artistic.

 A method of manufacturing this material has the significant drawback that its implementation requires a large amount of thermal energy to penetrate the material throughout its thickness. The decorative and structural layers of this material in the manufacturing process are subjected to melt and alloy with each other. A known method of manufacturing this material does not use such qualities of glass-silica-cement as its exceptional adhesion to materials prepared on a cement-sand basis. This quality is expressed by the coincidence of the coefficients of thermal expansion of materials: glass-silica-cement and those obtained on a cement-sand basis. In addition, as a result of the features of its manufacture, glass silica fume has porosity on its back side, which facilitates the penetration of a cement-containing binder into it. Therefore, when connecting, for example, glass-silica-reinforced concrete slabs with the concrete surface of the building using cement-sand mortar, such plates do not tear off the surface of the building during prolonged exposure to the environment. A known method of manufacturing a decorative glass-silica-reinforced concrete slabs containing decorative and structural layers by obtaining the compositions of the components of the layers, filling them into a mold, subsequent heat treatment and cooling (RU Pat. 2141457 for 1999). When implementing this method, both decorative and structural layers are subjected to heat treatment. The latter is from 50 to 80% of the total mass of the plate. This feature significantly slows down the heat treatment of the workpiece, reducing the productivity of the line as a whole. An object of the invention is to reduce the cost of manufacturing glass-siliceous plates by reducing the cost of thermal energy in their production, increasing the productivity of plants producing plates, as well as expanding the functionality of the material. The technical problem is carried out by the fact that in the method of manufacturing decorative glass-siliceous plates containing decorative and structural layers, by obtaining the compositions of the components of the layers, filling them into a mold, subsequent heat treatment and cooling, a decorative layer is first made with a reverse relief surface, including the upper part and the lower porous part moreover, sand with a grain size of up to 1 mm is additionally introduced into the composition of the components of the lower part, then a mixture of structural components is fed to the decorative layer the layer in the amount necessary to obtain plates of a fixed thickness, and with additives that provide a solidification layer at ambient temperature, and the plate - the required physical and mechanical characteristics. The technical problem is also carried out by the fact that sand is introduced into the lower part of the decorative layer in an amount of 40% or more by weight, and the relief of the reverse surface of the decorative layer is provided by pressing glass granules into the sand by a value of 0.5 to 2/3 of their height, which is carried out before applying to it the remaining components of the decorative layer. In this case, the glass granules are placed on a layer of sand in a separate form, at a distance from each other, ensuring their non-fusion with each other during subsequent heat treatment.

 When implementing this method, a significant part of the manufactured material, comprising from 0.5 to 0.8 part of its mass, does not require high-temperature processing in the furnace and at the same time a significant expenditure of thermal energy to create its structural layer and connection with the decorative one. This is ensured by a set of certain techniques that ensure their "cold" connection, taking into account the characteristics of glass-silica-cement, from which a decorative layer of material is made. As for the acquisition of the specified material strength, heat-shielding and other characteristics by the lower layer of the material, they are acquired by introducing certain additives known in the construction industry into its composition. The use of high-temperature processing of the material is applicable only for the manufacture of its decorative layer. Therefore, according to the invention, this will accelerate its passage through the thermal units by reducing the thickness of the material melted in the furnace. This circumstance contributes to an increase in the productivity of heat generating units, and, consequently, to the entire production line, which, in turn, will also have a positive effect on reducing the cost of the material.

 The invention is illustrated by figures explaining the technological position, where in Fig.1 is shown p.1 - sand layer in thermoform, p.2 - granule distribution grid, p.3 - glass granules to create a relief of the decorative layer.

 Figure 2 - position when the granule distribution grid is in a state of impact on the glass granules.

 Figure 3 - position when the glass granules that create the relief of the reverse surface of the decorative layer are pressed into the sand layer of the thermoform by a value of from 0.5 to 2/3 of their height.

 FIG. 4 - position when the components of the decorative layer are applied to the forms of the glass granules pressed into the sand layer, item 4.

 5 is a hard decorative layer with a reverse embossed surface formed by molten glass granules.

 FIG. 6 - a fragment of a fiberglass plate with a molded technological recess for fixing it, p. 6.

 Fig.7 - the same with embedded in it fasteners, PP.7, 8.

 EXAMPLES OF IMPLEMENTATION OF THE METHOD.

 Example 1

One of the options for the manufacture of tiled decorative structural material for facing the outer walls of buildings and structures is considered. First, to ensure the relief, the back side of the produced decorative layer in the thermoform place a sand layer with a thickness of 5 mm and even it. Then, a granule distribution grid in the form of a baking sheet with a flat perforated bottom corresponding to the area of the material to be filled is placed on the mold sand. The perforation holes of the bottom correspond to the size of the glass granules. On the upper side of the baking sheet placed slotted tray with granules, which is mounted with the possibility of movement along the baking sheet. The tray is moved along the bottom of the baking sheet and the perforation of the latter is filled with glass granules. Then, with the same baking sheet, lifting it above the glass granules that have fallen through the perforation of the bottom onto the mold sand, and lowering it again, press the glass granules into the sand and leave them slightly protruding there. After that, the lower part of the decorative layer, consisting of granular powder cullet and ground or fine sand, fractions up to 0.8 mm, and in an amount of from 40 wt.%, Is fed onto the mold sand. The filling of the layer is completed by feeding the upper part of the decorative layer, consisting, for example, of colored glass granules of red and green colors and brown glass powder. The composition of the components of the decorative layer in the thermal module is subjected to sintering in the heat shock mode at a temperature of 960 ^o C. After which the mold with the workpiece is cooled, it is removed in the form of a hard shell with a size of 0.8 • 0.8 m, a thickness of 4 mm (not counting the height of the embossed granule-like protrusions) of sintered and melted components of the decorative layer. The front side of the decorative layer is smooth, fire-polished, with a decorative two-color pattern on the entire surface, on which color images of granules bordered by brown veins are visible. The reverse side of the decorative layer extracted from the mold is embossed, covered with sand. The relief on the back side of the layer was provided by previously pressed into the sand form and melted in it large granules of cullet melted to the body of the decorative layer and also covered with sand. The reverse side of the decorative layer in its lower part contains the smallest pores with an exit to the outside. They are an important component of the created capillary system of the plate, which will work from the moment the plate is installed on the outer wall of the object. The work of this system is to provide moisture pulsation from the wall to the lower part of the decorative layer and back caused by temperature fluctuation of the medium. The shell of the decorative layer removed from the mold is laid with its face on the surface of the desktop. Around its contour, a shell is placed with a wall height corresponding to the thickness of the plate being manufactured. After that, a structural layer is applied to the reverse embossed surface of the decorative layer. It is prepared, for example, in the form of a viscous aqueous mixture of cement and sand in a ratio of 1: 2. Superplasticizer is introduced into it in an amount of 0.5-0.7 wt.% Cement to increase the water resistance and frost resistance of the structural layer by 2-4 times and the strength by 10-15 MPa. The mixture is filled with a shell over the entire height and the layer is compacted. After surface hardening of the structural layer, the shell is removed, and the workpiece is sent to the rack for further strength, and then cut along the contour.

 Example 2

 The example highlights the distinctive features of the manufacture of decorative tiles used for interior decoration. Since the temperature difference does not affect the facing materials inside the room, as on the plates located outside the buildings, the latter are prepared without the sharply pronounced relief of its reverse side provided by individual glass granules. At the same time, glass granules are not embedded in the sand and the composition of the components of the decorative layer is fed directly to the sand forms. First, its lower part, containing from 20% ground sand, fractions up to 0.2 mm, is fed, the rest is cullet in the form of a mixture of granules and powder. Then serves a mixture consisting of granules of milky color and a clear glass powder. After heat treatment, a decorative layer is obtained in the form of a shell, 4 mm thick and 0.8 • 0.8 m in size. The front side of the decorative layer is smooth, fire-polished, with a decorative pattern on the entire surface in the form of frosted granules bordered by transparent veins. The reverse side of the decorative layer extracted from the form is rough-sandy. The gypsum binder with a filler, a porous material of KSV, whose bulk density is 10 times lighter than ordinary sand, is introduced into the composition of the structural layer of plates for the internal wall cladding as additives to ensure its hardening at ambient temperature. The introduction of such a material in the composition of the structural layer of the plate gives the latter soundproofing qualities. The mixture is prepared according to GOST 28013-98. The adhesive strength of the layer is 0.8 MPa.

 Example 3

For the production of decorative structural material in the form of large sheets: 2.4 • 1.6 m 10 mm thick, used for the manufacture of wall panels, plumbing, decorative fencing of balconies and loggias, the decorative layer is prepared, as in example 1. Then, from the shells of the decorative layer , trimmed around the office, pick up a decorative layer of large sheet material, laying the shell on a pallet of the appropriate size, fix them from displacement, then, as in the above examples, lay the structural layer, vibroform or pop. A structural layer of such a structural material is prepared from Portland cement, sand, asbestos fiber, Extra additives GOST 24211-91 in an amount of 2-3 wt.% With the addition of water. The tensile strength of such a structural material in bending is 230 kgf / cm ² , water absorption from the side of the decorative surface is 0.24%. Instead of asbestos fibers, fiberglass or mesh is used to reinforce the structural layer. To fasten the plates to the place of their installation with the help of rack-and-pinion elements in the structural layer of the material, the necessary recesses are formed or fasteners are embedded in it during molding (Fig.6, 7). Thus, varying the composition of the components of the structural layer of materials, the introduction of various additives change the physical and mechanical characteristics of the structural material with a separately made glass-silica decorative layer. But among other things, you can also change its functional applicability. For example, the material can be decorative and at the same time heat-shielding, light if pore-forming additives or pre-foamed granules of the filler are introduced into the composition of the structural layer. By introducing additional reinforcing fibers or mesh into its structural layer, it becomes more bending and can be used in this case as a roofing material that combines the above decorative qualities with functional ones. This functional diversity of the material during the implementation of the method becomes possible due to the following qualities of glass silica used in the decorative layer. Firstly, the coincidence of its KTP with KTR cement-bonding materials and products from them. Secondly, the porosity of that part of the decorative layer that faces its other layers or the surface of structures. Thirdly, the relief of the reverse sandy surface of the decorative layer. As a result of the combination of these qualities, the prefabricated decorative layer in the structural material does not tear away from its second layer during prolonged use of the product and a sharp change in ambient temperature. In addition, the decorative layer protects the surface to be coated from moisture, aggressive chemical and radiation manifestations of the environment, providing it with the above advantages.

Claims (4)

 1. A method of manufacturing a decorative glass-siliceous slabs containing decorative and structural layers by obtaining compositions of the components of the layers, filling them into a mold, subsequent heat treatment and cooling, characterized in that the decorative layer is first made with a reverse relief surface, including the upper part and the lower porous part moreover, sand with a grain size of up to 1 mm is additionally introduced into the composition of the components of the lower part, then a mixture of components of the structural layer is fed to the decorative layer, necessary to obtain plates of a fixed thickness, and with additives that provide a hardening layer at ambient temperature, and the plate - the required physical and mechanical characteristics.  2. The method according to p. 1, characterized in that the sand is introduced into the lower part of the decorative layer in an amount of from 40 or more weight. %  3. The method according to p. 1, characterized in that the relief of the reverse surface of the decorative layer is provided by pressing glass granules into the sand by a value of from 0.5 to 2/3 of their height, which is carried out before applying the remaining components of the decorative layer to it.  4. The method according to any one of paragraphs. 1.3, characterized in that the glass granules are placed on a sand layer of the mold separately, at a distance from each other, ensuring their non-fusion with each other during subsequent heat treatment.

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