US3615963A - Panels from settled particles liquid binder and absorbent layer - Google Patents

Panels from settled particles liquid binder and absorbent layer Download PDF

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Publication number
US3615963A
US3615963A US788804A US3615963DA US3615963A US 3615963 A US3615963 A US 3615963A US 788804 A US788804 A US 788804A US 3615963D A US3615963D A US 3615963DA US 3615963 A US3615963 A US 3615963A
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United States
Prior art keywords
solid particles
binder
layer
absorbent layer
bonding agent
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Expired - Lifetime
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US788804A
Inventor
Karl L B Johansson
Karl Oskar Wikholm
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Cebem AB
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Cebem AB
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B15/08—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C67/00—Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00
    • B29C67/24—Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00 characterised by the choice of material
    • B29C67/242—Moulding mineral aggregates bonded with resin, e.g. resin concrete
    • B29C67/243—Moulding mineral aggregates bonded with resin, e.g. resin concrete for making articles of definite length
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F13/00—Coverings or linings, e.g. for walls or ceilings
    • E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
    • E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
    • E04F13/18—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements of organic plastics with or without reinforcements or filling materials or with an outer layer of organic plastics with or without reinforcements or filling materials; plastic 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
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
    • Y10T156/10—Methods of surface bonding and/or assembly therefor
    • Y10T156/1089—Methods of surface bonding and/or assembly therefor of discrete laminae to single face of additional lamina
    • Y10T156/109—Embedding of laminae within face of additional laminae

Definitions

  • the invention is concerned with wall panels and other construction units comprising a mixture of solid particles and liquid resinous bonding agent, said mixture being distributed on a base in such a manner that the volume of bonding agent exceeds the volume of the spaces between said solid particles.
  • the solid particles are now allowed to settle and the excess bonding agent is allowed to rise to the top of said solid particles so as to form an outer layer, into which one side of an absorbent layer is applied to absorb the bonding agent, which finally is cured. In this manner there will be obtained a strong composite construction unit having a smooth surface.
  • the present invention relates to the manufacture of flat or curved units, wall panels or the like for containers, silos, pipes, walls, roofs, floors or other building units, for example.
  • a particular object of the invention is to manufacture units which are durable, tight, strong and relatively cheap to manufacture.
  • this is achieved by a combination of manufacturing steps including spreading out a mixture of solid particles and liquid resinous binder on a base, the quantity of said binder exceeding the volume of the spaces between the solid particles, subsequently allowing the solid particles to settle, forming from the excess binder an outer layer, inserting into said layer one side of an absorbent layer to at least partially absorb this excess and finally curing said binder in a suitable known manner.
  • H6. 1 shows a section of a layer of the panel during manufacture
  • FIG. 2 shows this layer ready made and FIG. 3 illustrates a later stage in the manufacture.
  • the manufacture may be carried out in the following manner:
  • a preferably uniform layer 3 of a mixture of liquid resinous binder and solid particles is spread by means of a scraper or doctor knife 2, or in some other way, onto a preferably fiat, nonabsorbent base l (for example a sheet of stainless steel) treated with release agent.
  • the quantity of binder should exceed the volume of the spaces between the solid particles.
  • the time taken before sedimentation has taken place and the air bubbles have ceased to rise to the surface is, inter alia, de endent on the density and size of the solid particles and the viscosity and surface tension of the liquid binder.
  • the excess binder rises to the surface and forms an outer layer 5.
  • the outer layer 5 is now combined with an absorbent layer 6 (for example corrugated board placed transversely, FIG. 3) which is pressed down into the outer layer so that the excess liquid binder will be absorbed into the absorbent layer 6.
  • On top of the absorbent layer 6 is now possibly applied a layer 8 with release agent applied on a reversed sheet 7, similar to the layer 3, 5, with the excess resinous binder 5 facing the absorbent layer 6 so as to cause the latter to absorb the resinous binder 5.
  • a rigid heart product is obtained.
  • spacing runners 9 between the sheets 1 and 7 which, with sufficient accuracy, give the finished product the correct thickness and ensure that it will be parallel and flat.
  • the layer 3 is spread as now described onto mouldable sheets on a flat base.
  • an intermediate layer or absorbent layer of sand mixed with a deficiency of polyester and curing agent is spread to the desired thickness on one of the sheets.
  • the sheet is then shaped to the desired radius.
  • the outer layer applied on the second sheet is placed on the top side of said absorbent layer.
  • the absorption capacity of the absorbent layer must be such that it absorbs a suitable quanti' ty of the excess liquid binder. if the absorbent layer has too great an absorption capacity, the settled part 4 is leached, which causes unsatisfactory adhesion between the layers.
  • the absorption capacity is insufficient, a layer will remain between the absorbent layer 6 and the settled layer 4.
  • the intermediate layer obtained in this way will have greater shrinkage than the two other layers where shrinkage is practicallly eliminated. Shrinkage tensions thus arising may cause cracking and/or deformation.
  • the liquid resinous binder may consist, for example, of an iso hthalic, phthalic, bisphenolic or other polyester to ether wit a suitable curing agent, for example in the form 0 hexamethylenetetramine.
  • a suitable curing agent for example in the form 0 hexamethylenetetramine.
  • the solid particles may consist, for example of sand having, for example an average particle size of 0.15 mm., of the type Baskarp-sand No. 7," cement, granular slag, metal powder or iron powder, etc.
  • the absorbent layer may consist, for example of a mixture of sand with a deficiency of polyester or concrete or corrugated pasteboard (so-called "Tvarwell).
  • Method ofmanufacturing flat or curved units, wall panels or the like comprising the steps of spreading out a mixture of solid particles and liquid resinous binder on a base, the quantity of said binder exceeding the volume of spaces between the solid particles, subsequently allowing the solid particles to settle and to form a settled layer of particles with binder therebetween, forming from the excess binder an outer layer, inserting into said outer layer one side of an absorbent layer to absorb at least partially said excess binder, and finally allowing said binder to harden.

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  • Engineering & Computer Science (AREA)
  • Structural Engineering (AREA)
  • Architecture (AREA)
  • Ceramic Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Civil Engineering (AREA)
  • Laminated Bodies (AREA)

Abstract

The invention is concerned with wall panels and other construction units comprising a mixture of solid particles and liquid resinous bonding agent, said mixture being distributed on a base in such a manner that the volume of bonding agent exceeds the volume of the spaces between said solid particles. The solid particles are now allowed to settle and the excess bonding agent is allowed to rise to the top of said solid particles so as to form an outer layer, into which one side of an absorbent layer is applied to absorb the bonding agent, which finally is cured. In this manner there will be obtained a strong composite construction unit having a smooth surface.

Description

United States Patent [72] Inventors lliarlhhulohenssong Karl Osltar Wilrholm, both of l lluslrvarna,
Sweden [21] Appl. No. 788,806
[22] Filed Jan. 3, 1969 [45] Patented Oct. 26, 1971 [73] Assignee Cebern Alrtiebolag .llonkoping, Sweden [32] Priority Jan. 119, 1968 [33] Sweden [54] PANELS FROM SETTLlEI) PARTICLES LIQUID BINDER AND ABSORBIENT LAYER [56] References Cited UNITED STATES PATENTS 3,440,189 4/1969 Sharp 156/622 3,490,969 1/1970 Schiff 156/622 FOREIGN PATENTS 898,317 6/1962 Great Britain 156/622 Primary Examiner-Leland A. Sebastian Attorney-Albert M. Parker ABSTRACT: The invention is concerned with wall panels and other construction units comprising a mixture of solid particles and liquid resinous bonding agent, said mixture being distributed on a base in such a manner that the volume of bonding agent exceeds the volume of the spaces between said solid particles. The solid particles are now allowed to settle and the excess bonding agent is allowed to rise to the top of said solid particles so as to form an outer layer, into which one side of an absorbent layer is applied to absorb the bonding agent, which finally is cured. In this manner there will be obtained a strong composite construction unit having a smooth surface.
PANELS FROM SETTLED PARTICLES LlIQUID BKNDER AND ABSORBIENT LAYER The present invention relates to the manufacture of flat or curved units, wall panels or the like for containers, silos, pipes, walls, roofs, floors or other building units, for example. A particular object of the invention is to manufacture units which are durable, tight, strong and relatively cheap to manufacture. According to the invention this is achieved by a combination of manufacturing steps including spreading out a mixture of solid particles and liquid resinous binder on a base, the quantity of said binder exceeding the volume of the spaces between the solid particles, subsequently allowing the solid particles to settle, forming from the excess binder an outer layer, inserting into said layer one side of an absorbent layer to at least partially absorb this excess and finally curing said binder in a suitable known manner.
According to one embodiment described, by way of example, with reference to the accompanying drawings in which H6. 1 shows a section of a layer of the panel during manufacture,
MG. 2 shows this layer ready made and FIG. 3 illustrates a later stage in the manufacture.
The manufacture may be carried out in the following manner:
A preferably uniform layer 3 of a mixture of liquid resinous binder and solid particles is spread by means of a scraper or doctor knife 2, or in some other way, onto a preferably fiat, nonabsorbent base l (for example a sheet of stainless steel) treated with release agent. The quantity of binder should exceed the volume of the spaces between the solid particles. When the mixture has been spread out the solid particles 4 settle on the base (FIG. 2) and at the same time air bubbles rise to the surface.
The time taken before sedimentation has taken place and the air bubbles have ceased to rise to the surface is, inter alia, de endent on the density and size of the solid particles and the viscosity and surface tension of the liquid binder. The excess binder rises to the surface and forms an outer layer 5. The outer layer 5 is now combined with an absorbent layer 6 (for example corrugated board placed transversely, FIG. 3) which is pressed down into the outer layer so that the excess liquid binder will be absorbed into the absorbent layer 6. On top of the absorbent layer 6 is now possibly applied a layer 8 with release agent applied on a reversed sheet 7, similar to the layer 3, 5, with the excess resinous binder 5 facing the absorbent layer 6 so as to cause the latter to absorb the resinous binder 5. When the resinous binder has cured a rigid hart product is obtained.
As is clear from FIG. 3, there are provided spacing runners 9 between the sheets 1 and 7 which, with sufficient accuracy, give the finished product the correct thickness and ensure that it will be parallel and flat.
in order to produce curved constructions, for example segments for cylinders, the layer 3 is spread as now described onto mouldable sheets on a flat base. When the layer 3 has settled, an intermediate layer or absorbent layer of sand mixed with a deficiency of polyester and curing agent is spread to the desired thickness on one of the sheets. The sheet is then shaped to the desired radius. When this has been clone, the outer layer applied on the second sheet is placed on the top side of said absorbent layer. The absorption capacity of the absorbent layer must be such that it absorbs a suitable quanti' ty of the excess liquid binder. if the absorbent layer has too great an absorption capacity, the settled part 4 is leached, which causes unsatisfactory adhesion between the layers. If the absorption capacity is insufficient, a layer will remain between the absorbent layer 6 and the settled layer 4. When the liquid binder has solidified, the intermediate layer obtained in this way will have greater shrinkage than the two other layers where shrinkage is practicallly eliminated. Shrinkage tensions thus arising may cause cracking and/or deformation.
The liquid resinous binder may consist, for example, of an iso hthalic, phthalic, bisphenolic or other polyester to ether wit a suitable curing agent, for example in the form 0 hexamethylenetetramine. These substances are only mentioned as examples which are suitable, and which, as is well known in the art, will harden or cure" without the application of extra heat or pressure.
The solid particles may consist, for example of sand having, for example an average particle size of 0.15 mm., of the type Baskarp-sand No. 7," cement, granular slag, metal powder or iron powder, etc. The absorbent layer may consist, for example of a mixture of sand with a deficiency of polyester or concrete or corrugated pasteboard (so-called "Tvarwell).
What we claim:
ll. Method ofmanufacturing flat or curved units, wall panels or the like, comprising the steps of spreading out a mixture of solid particles and liquid resinous binder on a base, the quantity of said binder exceeding the volume of spaces between the solid particles, subsequently allowing the solid particles to settle and to form a settled layer of particles with binder therebetween, forming from the excess binder an outer layer, inserting into said outer layer one side of an absorbent layer to absorb at least partially said excess binder, and finally allowing said binder to harden.
2. Method according to claim 1, wherein a similar unit consisting of a settled layer of solid particles with binder therebetween and an outer layer of excess binder is applied on an other opposite side of said absorbent layer with the excess binder facing said opposite side, after which the binder is allowed to harden on both sides of the absorbent layer simultaneously.
t l t a l

Claims (1)

  1. 2. Method according to claim 1, wherein a similar unit consisting of a settled layer of solid particles with binder therebetween and an outer layer of excess binder is applied on an other opposite side of said absorbent layer with the excess binder facing said opposite side, after which the binder is allowed to harden on both sides of the absorbent layer simultaneously.
US788804A 1968-01-19 1969-01-03 Panels from settled particles liquid binder and absorbent layer Expired - Lifetime US3615963A (en)

Applications Claiming Priority (1)

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SE765/68A SE315713B (en) 1968-01-19 1968-01-19

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US (1) US3615963A (en)
JP (1) JPS528352B1 (en)
CH (1) CH473667A (en)
DE (1) DE1901708A1 (en)
DK (1) DK128949B (en)
FR (1) FR1600308A (en)
GB (1) GB1216171A (en)
NL (1) NL6900656A (en)
NO (1) NO121178B (en)
SE (1) SE315713B (en)

Cited By (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4208228A (en) * 1978-07-10 1980-06-17 Lennart Johansson Method of making building panel structure
US4232658A (en) * 1977-12-08 1980-11-11 Gessford James D Solar collector panel
US4261933A (en) * 1978-10-19 1981-04-14 Water Pollution Control Corporation Diffusion element
US4792466A (en) * 1986-05-14 1988-12-20 Micropore International Limited Method of making panels of microporous thermal insulation
US5177124A (en) * 1987-08-19 1993-01-05 Intaglio Ltd. Plastic molded pieces having the appearance of a solid metallic piece
US5384150A (en) * 1992-12-28 1995-01-24 Heeps; James W. Process for making a cooked, pureed meat product
WO1999000235A1 (en) * 1997-06-26 1999-01-07 Questech Corporation In mold bonded composites and a method for manufacturing the composites
WO1999018150A1 (en) * 1997-10-07 1999-04-15 Questech Corporation In mold bonded thin composites and a method for manufacturing the composites
WO2018111106A3 (en) * 2016-12-16 2018-07-26 Innovative Stone Technologies B.V. A method for manufacturing a slab

Cited By (13)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4232658A (en) * 1977-12-08 1980-11-11 Gessford James D Solar collector panel
US4208228A (en) * 1978-07-10 1980-06-17 Lennart Johansson Method of making building panel structure
US4261933A (en) * 1978-10-19 1981-04-14 Water Pollution Control Corporation Diffusion element
US4792466A (en) * 1986-05-14 1988-12-20 Micropore International Limited Method of making panels of microporous thermal insulation
US5177124A (en) * 1987-08-19 1993-01-05 Intaglio Ltd. Plastic molded pieces having the appearance of a solid metallic piece
US5280052A (en) * 1987-08-19 1994-01-18 Intaglio Ltd. Plastic molded pieces having the appearance of a solid metallic piece
US5384150A (en) * 1992-12-28 1995-01-24 Heeps; James W. Process for making a cooked, pureed meat product
WO1999000235A1 (en) * 1997-06-26 1999-01-07 Questech Corporation In mold bonded composites and a method for manufacturing the composites
WO1999018150A1 (en) * 1997-10-07 1999-04-15 Questech Corporation In mold bonded thin composites and a method for manufacturing the composites
WO2018111106A3 (en) * 2016-12-16 2018-07-26 Innovative Stone Technologies B.V. A method for manufacturing a slab
CN110312612A (en) * 2016-12-16 2019-10-08 创新石科技公司 The manufacturing method of slab
CN110312612B (en) * 2016-12-16 2021-08-03 创新石科技公司 Manufacturing method of slab
US11260562B2 (en) * 2016-12-16 2022-03-01 Innovative Stone Technologies B.V. Method for manufacturing a slab

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DE1901708A1 (en) 1970-08-13
DK128949C (en) 1975-01-20
CH473667A (en) 1969-06-15
GB1216171A (en) 1970-12-16
DK128949B (en) 1974-07-29
NL6900656A (en) 1969-07-22
SE315713B (en) 1969-10-06
JPS528352B1 (en) 1977-03-08
NO121178B (en) 1971-01-25
FR1600308A (en) 1970-07-20

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