Process for the manufacture of block artifacts and block artifact obtained by said process

Abstract

Process for the manufacture of block artifacts, comprising at least the following phases: - supplying of at least one base component (2) comprising silicates or alumino silicates and at least one reagent (3); - first mixing of the base component (2) and the reagent (3) to obtain a liquid or semisolid geopolymer mixture (4); - second mixing of the geopolymer mixture (4) with at least one inert material (7) to obtain a geopolymer slurry (8); - casting of the geopolymer slurry (8) into at least one forming mold (9); - forming at least one block artifact (1) from the geopolymer slurry (8) A white-coloured block artifact (1) obtained by the process is also claimed.

Description

[0001] PROCESS FOR THE MANUFACTURE OF BLOCK ARTIFACTS AND BLOCK ARTIFACT OBTAINED BY SAID PROCESS

[0002] Technical Field

[0003] The present invention relates to a process for the manufacture of block artifacts. Background Art

[0004] With particular reference to the field of wall and / or floor coverings, technological processes are known in which one or more materials are mixed in predetermined weight ratios to a base component in order to obtain a liquid / semi-solid mixture which can be used in the manufacture of block artifacts.

[0005] In this regard, the use of resin and quartz as a base component and inert filler, respectively, is quite common in the production of block artifacts intended for the installation in indoor environments such as, e.g., on kitchen countertops / worktops or similar locations.

[0006] In this case, the mixture of the aforementioned substances is cast within a dedicated mold and is then subjected to forming treatments (i.e., drying and polishing) that allow it to be consolidated and transformed into the finished product.

[0007] It is important to draw attention to the fact that, by virtue of its constituent components, this mixture has rather high viscosity values that make it necessary to take certain precautionary measures aimed to prevent the adhesion thereof to the mold.

[0008] In this very regard, it is common practice to line the mold with several layers of paper to prevent direct contact between the mixture and the mold and to employ a special vacuum vibrating press to keep the mixture stirring as a result of its casting.

[0009] It is evident to see, at this point, that the process just described suffers from several major drawbacks.

[0010] First of all, it should be noted that, although justified by the rheology of the mixture, the aforementioned expedients severely limit the practicality of this process and result in major technical complications which, in addition to negatively affecting the production capacity, increase the risk of producing block artifacts that are qualitatively unsatisfactory and, therefore, to be discarded. What’s more, it is clear how necessarily having a vibrating press makes the process under consideration decidedly costly in economic terms and ends up severely penalizing the company’s budget.

[0011] In addition, the high toxicity that distinguishes the resin requires the adoption of appropriate personal protective equipment by the personnel involved, thus entailing an additional item of expense to be added to the already high costs outlined above.

[0012] Nonetheless, the resin also has high photosensitivity and, therefore, undergoes even major aesthetic-functional changes when exposed directly to light, as is the case of outdoor environments.

[0013] It is easy to appreciate how this fact strongly impacts the versatility of this process, thus limiting the possible locations for the installation of the block artifacts thus produced to indoor environments only.

[0014] In this regard, there are also known materials, marketed under the name of “ultra cements”, which are used for the production of block artifacts also intended for installation on kitchen countertop s / worktops.

[0015] It has, however, been observed that these materials suffer from problems quite similar to those reported for mixtures obtained from quartz and resin and that, therefore, their use in the production of block artifacts is equally inefficient, costly and, for these reasons, inconvenient.

[0016] Description of the Invention

[0017] The main aim of the present invention is to devise a process for the manufacture of block artifacts distinguished by simplified implementation and less costly than known processes.

[0018] Within that main aim, one object of the present invention is to devise a process for the manufacture of block artifacts making use of non-toxic components that are resistant to light-induced degradation.

[0019] Another object of the present invention is to devise a process for the manufacture of block artifacts which allows the aforementioned drawbacks of the prior art to be overcome within the framework of a simple, rational, easy and effective to use as well as affordable solution. The aforementioned objects are achieved by this process for the manufacture of block artifacts having the characteristics of claim 1.

[0020] Other characteristics and advantages of this invention will become more apparent from the description of a preferred, but not exclusive, embodiment of a process for the manufacture of block artifacts, illustrated by way of an indicative, yet nonlimiting example, in the accompanying tables of drawings in which:

[0021] Figure 1 illustrates the first mixing phase of the process according to the invention;

[0022] Figure 2 illustrates the second mixing phase of the process according to the invention;

[0023] Figure 3 illustrates the casting phase of the process according to the invention;

[0024] Figure 4 illustrates the cutting step of the process according to the invention;

[0025] Figure 5 illustrates the block artifact obtained from the process according to the invention.

[0026] Embodiments of the Invention

[0027] With particular reference to these figures, reference numeral 1 globally denotes a block artifact made in accordance with the process according to the invention.

[0028] First of all, the process for the manufacture of block artifacts comprises the phases of: supplying of at least one base component 2 comprising silicates or aluminosilicates and at least one reagent 3; and of first mixing of the base component 2 and the reagent 3 to obtain a liquid or semisolid geopolymer mixture 4 (Figure 1).

[0029] Preferably, the base component 2 is selected from the list comprising: fly ash (Class F), blast furnace slag, metakaolin, microsilica.

[0030] As for the reagent 3, it is preferably an alkaline or acid solution.

[0031] In this case, the reagent 3 comprises a sodium silicate solution, or potassium silicate solution, or mixtures thereof.

[0032] Advantageously, the reagent 3 comprises phosphoric acid.

[0033] Conveniently, the above phosphoric acid has a molar concentration of 8.5 M. Furthermore, it cannot be ruled out from the scope of this disclosure that the reagent 3 may be seawater.

[0034] Conveniently, the first mixing phase comprises at least one step of first introduction of the base component 2 and of the reagent 3 within at least one mixing chamber 5.

[0035] In particular, the mixing chamber 5 is provided with special mixing means 6, e.g. the type of mixing paddles / augers which can effectively mix the base component 2 and the reagent 3 to obtain the geopolymer mixture 4.

[0036] The process then comprises at least a second mixing of the geopolymer mixture 4 with at least one inert material 7 to obtain a geopolymer slurry 8 (Figure 2). Conveniently, the second mixing is carried out within the mixing chamber 5, but the possibility of performing this phase in a different location, e.g. within a dedicated and different mixing chamber, cannot be ruled out.

[0037] As for the inert material 7, it is preferably in the form of a powder with a predetermined grain size.

[0038] Preferably, the inert material 7 comprises at least one of quartz, marble or mixtures thereof.

[0039] The second mixing can be directly carried out as a result of the first mixing. Alternatively, the process comprises a phase of additional mixing of one or more additives which is carried out between the phase of first mixing and the phase of second mixing.

[0040] Specifically, the additives are selected from the list comprising: anti-foaming agents, fibers, waterproofing agents, fluidizing agents, water or mixtures thereof. The addition of these additives is intended to allow for varying the texture of the geopolymer slurry 8 obtained at the end of mixing.

[0041] Specifically, the phase of additional mixing comprises a respective additional phase of introducing one or more of the aforementioned additives into the mixing chamber 5.

[0042] The process comprises, again, a phase of casting the geopolymer slurry 8 into at least one forming mold 9 (Figure 3).

[0043] Specifically, as shown in the figures by way of example, the forming mold 9 is in fluid-operated communication with the mixing chamber 5.

[0044] In this way, after the geopolymer mixture 4 has been obtained, it can be made directly flow into the forming mold 9, thus increasing the efficiency and production output of the process according to the invention.

[0045] Again, the process comprises at least one phase of forming at least one block artifact 1 from the geopolymer slurry 8.

[0046] Specifically, the phase of forming comprises at least one step of drying the geopolymer slurry 8.

[0047] In particular, the step of drying allows the geopolymer slurry 8 to be consolidated and the latter to take on a conformation which is complementary to that of the forming mold 9.

[0048] In addition, the phase of forming comprises at least one step of cutting the geopolymer slurry 8 carried out subsequent to the step of drying.

[0049] In this case, the step of cutting is carried out by means of cutting means 10 adapted to obtain a plurality of block artifacts 1 and shown by way of example in Figure 4.

[0050] Note how the cutting means 10 allow the size of the block artifacts 1 obtained through their use to be varied substantially at will, benefiting the possible applications in which they are profitably employed and the overall versatility of the process.

[0051] Advantageously, the phases of mixing, the phase of casting and the phase of forming are repeated cyclically.

[0052] Specifically, the phase of first mixing is carried out at the same time as the phase of forming.

[0053] In other words, the process can be carried out in a continuous cycle; thus, it is possible not only to drastically increase the production output thereof, but also to perform it “in situ”, that is, directly at the place corresponding to the final destination of the block artifact 1.

[0054] It is noted in this regard, among other things, that the process according to the invention makes it easy to adjust the amount of geopolymer slurry 8 produced depending on the number and size of block artifacts 1 to be manufactured, benefiting overall efficiency as well as reducing material waste.

[0055] According to a further aspect, this invention also covers a block artifact 1 obtained by the process according to the invention and illustrated by way of an example in Figure 5.

[0056] Specifically, the block artifact 1 thus produced is white in color.

[0057] The block artifact 1 obtained by the process according to the invention shows, in particular, significantly improved physical-mechanical properties compared with the block artifacts obtained through the known processes.

[0058] Specifically, the aforementioned product has properties of resistance to direct exposure to the sun and UV rays and, therefore, does not undergo structural degradation processes in the outdoor environment.

[0059] This fact makes it possible to greatly increase the possible applications for use of the block artifact 1 and, in particular, to use the latter profitably in both indoor environments and outdoor environments.

[0060] Still, such block artifact 1 also shows remarkable resistance to fire, to acid or sulfate attack, to freeze / thaw cycles or to storm cycles with temperatures ranging from 20°C to 60°C.

[0061] It is easy to appreciate how, by virtue of the characteristics just outlined, the block artifact 1 proves to be not only more versatile than known artifacts but also significantly better performing and structurally strong, ultimately proving to be more convenient and practical in its use.

[0062] It has in practice been ascertained that the described invention achieves the intended objects.

[0063] In particular, the process according to the invention is marked by a simplified and less costly implementation than known processes and is, for this reason, significantly cheaper in its implementation.

[0064] In this regard, it should be noted that by making use of completely non-toxic components which are resistant to light-induced degradation, the process according to the invention is significantly more practical and cost-effective than known processes, as it can be carried out both in indoor environments and outdoor environments. Finally, the possibility of carrying out the phases of the process in a continuous cycle makes it possible to greatly increase the versatility and production output thereof, thus allowing the block artifact to be produced directly “in situ”, that is, at the place corresponding to its final destination.

Claims

CLAIMS1) Process for the manufacture of block artifacts, characterized by the fact that it comprises at least the following phases: supplying of at least one base component (2) comprising silicates or alumino silicates and at least one reagent (3); first mixing of said base component (2) and said reagent (3) to obtain a liquid or semisolid geopolymer mixture (4); second mixing of said geopolymer mixture (4) with at least one inert material (7) to obtain a geopolymer slurry (8); casting of said geopolymer slurry (8) into at least one forming mold (9); forming at least one block artifact (1) from said geopolymer slurry (8).2) Process according to claim 1, characterized by the fact that said phases of mixing are carried out within at least one mixing chamber (5) which is in fluid- operated communication with said forming mold (9).3) Process according to one or more of the preceding claims, characterized by the fact that said phase of first mixing, said phase of second mixing, said phase of casting and said phase of forming are repeated cyclically and by the fact that said phase of first mixing is carried out at the same time as said phase of forming.4) Process according to one or more of the preceding claims, characterized by the fact that said phase of forming comprises at least one step of drying said geopolymer slurry (8).5) Process according to claim 4, characterized by the fact that said phase of forming comprises at least one step of cutting said geopolymer slurry (8) carried out subsequently to said step of drying.6) Process according to one or more of the preceding claims, characterized by the fact that it comprises at least one phase of additional mixing one or more additives selected from the list comprising: anti-foaming agents, fibers, waterproofing agents, fluidizing agents, water or mixtures thereof, said phase of additional mixing being carried out between said phase of first mixing and said phase of second mixing.7) Process according to one or more of the preceding claims, characterized bythe fact that said reagent (3) is an alkaline or acid solution.8) Process according to one or more of the preceding claims, characterized by the fact that said inert material (7) is in the form of a powder with a predetermined grain size. 9) Process according to one or more of the preceding claims, characterized by the fact that said inert material (7) comprises at least one of quartz, marble or mixtures thereof.10) Block artifact (1) obtained by the process according to one or more of the preceding claims, characterized by the fact of being white in color.

Images