Stock material or miscellaneous articles – Composite – Of silicon containing
Reexamination Certificate
2002-02-01
2004-05-25
Dawson, Robert (Department: 1712)
Stock material or miscellaneous articles
Composite
Of silicon containing
C428S454000, C427S554000, C427S555000, C427S387000, C125S001000, C125S038000
Reexamination Certificate
active
06740417
ABSTRACT:
The object of the invention relates to a surface-treated mineral material and a process for their production. A particular planned use of the invention relates to surface optimized floor and wall coverings made from natural or artificial stone for indoor and outdoor areas, in particular optimized with respect to wear resistance, soil repelling and slip resistance.
Slips are one of the most frequent causes of accidents in Germany. The severity of such accidents is usually underestimated. In order to increase the security of footsteps the shoe soles and floors both must be embodied in a slip resistant manner. Predominantly, this is necessary in floor coverings that are exposed to slip enhancing media. In many areas of public life, e.g., on side walks and public courts, and, in private areas as well it is common to use blasted, singed, kerneled, layered, smooth, or serrated, polished, and etched floor coverings in dry as well as in wet areas and transitional areas. In addition to their use as floor coverings, such coverings are also used for wall and frontal surfaces, preferably in outdoor regions, but in indoor regions as well. Here, it is desirable to durably maintain the slip resistant effect and, simultaneously, achieve a surface as stain resistant, washable, and wear resistant as possible, that is embodied with steam permeable, hydrophobic, and oleophobic features.
Frequently, indoor and outdoor floor and wall areas are covered with natural and artificial stone. A variety of regulations must be observed in relation to security of footsteps. Thus, in many areas only heavily structured surfaces can be used. Such surfaces have production-related disadvantages.
The evaluation of surfaces can be performed, e.g., according to the following standardized processes:
DIN 51130, the determination of the slip resistant characteristics for work places and work areas exposed to danger of slipping,
DIN 51097, the determination of the slip resistant characteristics for wet loaded bare foot areas —stepping processes,
ASTM 1028, static coefficient of friction or
ISO 10.545 part 17 (Method B: Static Slider).
A variety of processes exist for the production and/or increase of slip resistant characteristics of floor coverings and for the production of various surface appearances and surface characteristics as well. Predominantly, their utilization depends on where and how the surface is to be used and what the builder requests with regard to surface appearance and surface characteristics. In the following, the most essential processes are briefly described:
1. Blasting
In blasting a blasting material corresponding to a desired roughness is thrown with high pressure onto the surface. The more or less hard blasting material causes an uneven roughness provided-with micro roughness and deadening of the surface. Additionally, production related fine dust particles adhere more or less durably to the stone surface in or at the joint mixtures.
2. Flame Jet Singeing
In flame jet singeing highly energetic fuel gas —oxygen flames are created by which the surfaces to be treated are briefly heated to a large extent. Due to the effect of the flames, the quartz crystals in the uppermost regions of the stone burst and parts of the stone melt; subsequently it solidifies in a glasslike manner, adheres comparatively loosely to the surface, and peels off when used.
3. Kerneling
Kerneling occurs by using a kerneling tool (kerneling hammer) which is provided with several, evenly positioned chisel tips. During the continuous motion of a work piece the kerneling hammer impacts the surface with a certain frequency. This results in a more or less intense shock of the composition with chippings and loosely or tighter adhering stone parts, dependent on the stone components. Production related superfine dust particles adhere more or less tightly in or to the composition mixtures.
4. Surface Coating
The coating of surfaces can be performed such that the surfaces are provided with, e.g., knobs and, thus, an increase in slip resistance is achieved. The stone is closed over its entire surface. This is disadvantageous after laying, since the water used for laying is blocked and the stone is damaged by rising water (steam pressure develops, e.g., which can burst the stone). The modification of the appearance characteristics is correlated to the coating used; this method is only of limited use in floor coverings, since wear cannot be prevented.
5. Rough Charging
In ore processing (blocks of natural or artificial stone), iron saw blades cut the blocks into rough slabs with a steel-sand mixture being added. Thus resulting in an unevenly rough surface. Production related fine dust and residue of the steel-sand mixture adhere in or at the stone surface. Depending on the type of stone and the present residue, corrosion processes begin when coming into contact with water, which can partially result in bursting of the composition and discoloration depending on the duration of the exposure.
6. Serrating
In ore processing (blocks of natural or artificial stone), iron saw blades cut the blocks are cut by means of diamond-stocked metal saw blades directly into standard size. Thus, resulting in a surface comparable to coarse polishing. The quickly rotating cutting disc and the continuous introduction of water press the production related fine dust particles into the natural formation of the stone surface. These fine dust particles partially adhere tightly to the stone formation; however, they separate from floor coverings when said floor is used.
7. Chemical Etching
Generally, in chemical etching of stone surfaces (using substances containing hydrofluoric acid) the soft parts are washed out first. The chemical composition and concentration must be adjusted to the stone surface, in order to prevent undesired damage, such as corrosion, for instance. Health hazardous vapors develop during processing.
8. Cutting and/or Polishing
Treatment of the surfaces by means of an abrasive medium, such as diamond dust, boron nitride, or corundum (fused alumina).
The described processes or similar processes using abrasive media and/or chisel-like tools achieve an increase in security of footsteps, however, they also cause structural shocks and chippings off the formation and, production related superfine dust particles deposit, partially adhering tightly. In some processes, it is also disadvantageous that the slip resistance is only achieved subsequent a post treatment at the point of use.
From DE A 2 053 110 a process for treating mineral surfaces is known with the surface initially being hydromechanically and subsequently treated with organo-silicide compositions causing hydrophobic effects. However, surfaces treated in such a way are not provided with the desired stain resistance.
From DE 195 18 270 a surface treated, slip resistant floor covering is known that does not show some of the above-mentioned disadvantages. Such a floor covering is produced by applying statistically distributed micro craters, invisible for the human eye, onto the surface of the floor covering by means of a laser.
The object of the invention is to provide highly slip resistant, stain resistant, and durable, wear resistant, weather resistant, free of fine dust, and optionally, refined surfaces, e.g., by means of polishing, made from mineral materials which are not provided with any of the disadvantages of prior art.
The object is attained according to the invention by providing a process, having at least two steps, for treating the surface of mineral materials, which comprises the following steps:
a) Laser radiation affecting the surface and
b) Application of an organo-silicide composition onto the surface.
The object of the surface treatment are mineral materials such as: natural stones, artificial stones, e.g., mineral agglomerates of resin compositions or cement compositions, ceramics or ceramic materials, earthen ware, or stone ware. The above-mentioned steps are preferably parts of a treatment process, essentially limited in duration, and occur prior to further treatment/utili
Fahrenkrog Herbert
Sievers Thomas
Dawson Robert
Hedman & Costigan P.C
Keehan Christopher
Sievers Thomas
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