Compositions: ceramic – Ceramic compositions – Refractory
Patent
1991-07-29
1993-09-14
Group, Karl
Compositions: ceramic
Ceramic compositions
Refractory
501155, 501 32, 106631, C04B 3518
Patent
active
052448509
DESCRIPTION:
BRIEF SUMMARY
DESCRIPTION OF INVENTION
This invention relates to a building product particularly, but not exclusively, for external use, such as a roofing tile, a flooring slab or a cladding panel.
In previous Patent No. GB 1174304 there is described a product comprising particles of granite embedded in a glassy material provided initially as an alkali metal silicate solution. However, the product requires a coating to make it impervious.
According to one aspect of the invention we provide a building product comprising slate particles (as herein defined) bonded together by a fused glassy binder.
By "particles" we mean, slivers or chips or fragments, (collectively called "fragments" herein) having a maximum dimension in the range 1 mm to 12 mm and/or slate powder having a maximum dimension of less than 1 mm and more than 0.075 mm and/or dust having a maximum dimension of less than 0.075 mm such that virtually all the slate dust passes through a B.S. sieve No. 200.
The building product may be a roofing slate, a floor slab or a cladding panel for examples.
According to a second aspect of the invention we provide a method of making a building product comprising the steps of mixing binder material and slate particles, heating the mixture sufficiently to cause the binder material at least to melt, and permitting the binder material to set to bond the slate particles together. The binder may be an alkali metal silicate binder material which contains between 30% and 40% by weight silicates including incidental solids.
The invention will now be described with reference to the following examples.
In a first example, a building product is made by melting recycled bottle glass which comprises a fused mixture of silica, calcium carbonate and sodium carbonate. The glass is heated to a temperature of at least 730.degree. C. and then particles of slate e.g. slate fragments (as herein defined) and slate powder and slate dust (as herein defined) are stirred into or otherwise mixed with the molten glass.
A blob of the slate/glass mixture is then placed into a mould to which pressure is then applied by means of a hydraulic press, which pressure assists in removing any voids from the mixture, and forces the mixture to fill the mould. The product may be reinforced with strands of or a grid of glass fibre and/or metal which may be placed in the mould during moulding, or may subsequent to moulding, be bonded to the product. The mixture is then permitted to set.
The mould may be for a single roofing slate although alternatively if desired, the mould may be for a sheet or layer of the mixture which after setting, is then cut into tiles of a required shape and size. Thus the mould may be adapted to facilitate providing lines of weakness between the individual tiles of the sheet or layer of mixture.
If desired, instead of using recycled ,bottle glass, any other desired recycled or other glass can be used such as flint glass or borosilicate glass for examples. In each case, the glass when set, provides a fused glassy binder.
The building product may be coloured by adding suitable colouring agents to the binder material when molten, to modify or change the colour of the product from the natural colour of the slate.
Alternatively, or additionally, instead of providing the binder material in the form of recycled glass, the binder material may comprise silicates which need to be heated sufficiently at least to fuse to form a glassy binder, or the binder may comprise a mixture of recycled glass and silicates such as alkali metal silicates. In either case, again colouring agents may be added.
A similar method to that described may be used to make a flooring slab or a cladding panel or any other building product as desired. The product thus made may require fabrication or finishing work to achieve an end product when removed from the mould.
In another, preferred example, a building product is made by mixing together a solution or suspension of an alkali metal silicate, such as sodium silicate, and slate particles. The alkali metal silicate solution or su
REFERENCES:
patent: 4822420 (1989-04-01), Burkhardt et al.
patent: 4992321 (1991-02-01), Kandachi et al.
Digive Limited
Group Karl
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