DE3835851C1 - Method of manufacturing artificial stones - Google Patents

Method of manufacturing artificial stones

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Publication number
DE3835851C1
DE3835851C1 DE3835851A DE3835851A DE3835851C1 DE 3835851 C1 DE3835851 C1 DE 3835851C1 DE 3835851 A DE3835851 A DE 3835851A DE 3835851 A DE3835851 A DE 3835851A DE 3835851 C1 DE3835851 C1 DE 3835851C1
Authority
DE
Germany
Prior art keywords
foam
compilation
water
barium carbonate
stones
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
Application number
DE3835851A
Other languages
German (de)
Inventor
Arturo 4000 Duesseldorf De Broggini
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Individual
Original Assignee
Individual
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from DE19883804884 external-priority patent/DE3804884A1/en
Application filed by Individual filed Critical Individual
Priority to DE3835851A priority Critical patent/DE3835851C1/en
Priority to EP89119483A priority patent/EP0365022B1/en
Priority to DE89119483T priority patent/DE58905965D1/en
Priority to AT89119483T priority patent/ATE96138T1/en
Application granted granted Critical
Publication of DE3835851C1 publication Critical patent/DE3835851C1/en
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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    • C—CHEMISTRY; METALLURGY
    • C12—BIOCHEMISTRY; BEER; SPIRITS; WINE; VINEGAR; MICROBIOLOGY; ENZYMOLOGY; MUTATION OR GENETIC ENGINEERING
    • C12N—MICROORGANISMS OR ENZYMES; COMPOSITIONS THEREOF; PROPAGATING, PRESERVING, OR MAINTAINING MICROORGANISMS; MUTATION OR GENETIC ENGINEERING; CULTURE MEDIA
    • C12N11/00—Carrier-bound or immobilised enzymes; Carrier-bound or immobilised microbial cells; Preparation thereof
    • C12N11/14—Enzymes or microbial cells immobilised on or in an inorganic carrier
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D39/00—Filtering material for liquid or gaseous fluids
    • B01D39/14—Other self-supporting filtering material ; Other filtering material
    • B01D39/20—Other self-supporting filtering material ; Other filtering material of inorganic material, e.g. asbestos paper, metallic filtering material of non-woven wires
    • B01D39/2027—Metallic material
    • B01D39/2051—Metallic foam
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D39/00—Filtering material for liquid or gaseous fluids
    • B01D39/14—Other self-supporting filtering material ; Other filtering material
    • B01D39/20—Other self-supporting filtering material ; Other filtering material of inorganic material, e.g. asbestos paper, metallic filtering material of non-woven wires
    • B01D39/2068—Other inorganic materials, e.g. ceramics
    • B01D39/2093—Ceramic foam
    • C—CHEMISTRY; METALLURGY
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    • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/001—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing unburned clay
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
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    • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/02—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing hydraulic cements other than calcium sulfates
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/02—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing hydraulic cements other than calcium sulfates
    • C04B28/10—Lime cements or magnesium oxide cements
    • C—CHEMISTRY; METALLURGY
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    • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/14—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing calcium sulfate cements
    • C—CHEMISTRY; METALLURGY
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    • C04B33/00—Clay-wares
    • C04B33/02—Preparing or treating the raw materials individually or as batches
    • C04B33/04—Clay; Kaolin
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    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
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    • C04B35/03—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on magnesium oxide, calcium oxide or oxide mixtures derived from dolomite
    • C04B35/057—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on magnesium oxide, calcium oxide or oxide mixtures derived from dolomite based on calcium oxide
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    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
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    • C04B35/16—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on silicates other than clay
    • C04B35/18—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on silicates other than clay rich in aluminium oxide
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    • C04B35/46—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on titanium oxides or titanates
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    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/626—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
    • C04B35/63—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B using additives specially adapted for forming the products, e.g.. binder binders
    • C04B35/6303—Inorganic additives
    • C—CHEMISTRY; METALLURGY
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    • C04B35/64—Burning or sintering processes
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    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/71—Ceramic products containing macroscopic reinforcing agents
    • C04B35/78—Ceramic products containing macroscopic reinforcing agents containing non-metallic materials
    • C04B35/80—Fibres, filaments, whiskers, platelets, or the like
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    • C04B38/00—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof
    • C04B38/10—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof by using foaming agents or by using mechanical means, e.g. adding preformed foam
    • C04B38/106—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof by using foaming agents or by using mechanical means, e.g. adding preformed foam by adding preformed foams
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C1/00—Building elements of block or other shape for the construction of parts of buildings
    • E04C1/40—Building elements of block or other shape for the construction of parts of buildings built-up from parts of different materials, e.g. composed of layers of different materials or stones with filling material or with insulating inserts
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    • C04B2235/32—Metal oxides, mixed metal oxides, or oxide-forming salts thereof, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
    • C04B2235/3205—Alkaline earth oxides or oxide forming salts thereof, e.g. beryllium oxide
    • C04B2235/3208—Calcium oxide or oxide-forming salts thereof, e.g. lime
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    • C04B2235/3205—Alkaline earth oxides or oxide forming salts thereof, e.g. beryllium oxide
    • C04B2235/3215—Barium oxides or oxide-forming salts thereof
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    • C04B2235/526—Fibers characterised by the length of the fibers

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  • Inorganic Chemistry (AREA)
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  • Architecture (AREA)
  • Geology (AREA)
  • Civil Engineering (AREA)
  • Curing Cements, Concrete, And Artificial Stone (AREA)

Abstract

Published without abstract.

Description

Gegenstand der vorliegenden Erfindung ist eine verbesserte Ausführungsform des Verfahrens zur Herstellung eines künstlichen Steins gemäß der deutschen Patentanmeldung P 38 04 884.1, der leicht und stabil sowie gegen Frost, Feuer und Witterung beständig ist und ein hohes Wärmedämmvermögen aufweist.The subject of the present invention is a improved embodiment of the method for the production an artificial stone according to the German patent application P 38 04 884.1, which is light and stable as well as against frost, Fire and weather is stable and high Thermal insulation has.

Steine, die teilweise die genannten Eigenschaften aufweisen, sind unter der Bezeichnung "Poroton" im Handel erhältlich. Es handelt sich hierbei um porige Hohllochziegel für Mauerwerk. Diese Ziegel sind wärmedämmend, schützen vor teuren Energieverlusten und sorgen für ein ausgeglichenes Raumklima. Solche Ziegel entsprechen auch statischen Anforderungen. Nachteilig ist jedoch, daß diese Steine immer noch ein relativ hohes Gewicht haben. Außerdem ist die Herstellung mit Umweltbelastungen verbunden, weil Styropor® oder andere Schaumkunststoffe zur Erzeugung der Poren verbrannt werden. Auch Blähton hat teilweise die genannten Eigenschaften. Er findet jedoch nur als Granulat Anwendung. Die Erstellung von Gußelementen ist nur durch Zusatz von Bindemitteln möglich. Stones, some of the properties mentioned are commercially available under the name "Poroton" available. These are porous hollow bricks for masonry. These bricks are heat-insulating, protect against expensive energy losses and ensure a balanced Indoor climate. Such bricks also correspond static Conditions. The disadvantage, however, is that these stones always still have a relatively high weight. In addition, the Production associated with environmental pollution because Styropor® or other foam plastics for the production of Pores are burned. Also expanded clay has partially the mentioned properties. He finds only as granules Application. The creation of castings is only by Addition of binders possible.  

Ferner sind mit Sägemehl und anderen Füllstoffen erstellte Leichtbausteine bekannt. Diese haben jedoch Nachteile, die darin zu sehen sind, daß Rückstände in Form von Asche nach dem Brand Salze bilden.They are also made with sawdust and other fillers Light building blocks known. However, these have disadvantages that it can be seen that residues in the form of ash after form salts in the fire.

Aus Probst: Handbuch der Betonindustrie, 1962, Seiten 157, 158, sind sogenannte Schaumbetone bekannt. Bei deren Herstellung werden feinkörnige Sand-Zement-Gemenge durch schaumbildende Mittel aufgetrieben, wobei Luftblasen entstehen, die als Poren zurückbleiben. Als schaumbildende Mittel werden Seifen eingesetzt. Da bei einfachem Rühren nur sehr lockere Schäume entstehen, müssen die Seifen in besonders schnellaufenden Rührwerken geschlagen werden, bis ein der Schlagsahne ähnliches stabiles Gebilde entsteht.From Probst: Handbook of Concrete Industry, 1962, pages 157, 158, so-called foam concretes are known. In their Production are fine-grained sand-cement mixture by foaming agent distended, with air bubbles arise, which remain as pores. As foam-forming Medium soaps are used. Because with easy stirring Only very loose foams arise, the soaps need be beaten in particularly fast-running agitators, until a whipped cream similar stable structure arises.

Probst: Handbuch der Betonsteinindustrie, 1962, S. 12, betrifft einen Barytzement, dessen Beständigkeit gegen Sulfate durch die Zugabe von kohlensaurem Barium gesteigert werden soll. Spezielle Angaben über quantitative Mengen und Schaumbaustoffe werden nicht gemacht.Probst: Handbuch der Betonsteinindustrie, 1962, p. 12, relates to a barytcement whose resistance to Sulfates increased by the addition of carbonate of barium shall be. Special information about quantitative quantities and foam building materials are not made.

Heuschkel-Muche: ABC Keramik, 1975, S. 23 und 166, beschreibt den Zusatz von Bariumcarbonat als Flußmittel. Hierbei wird darauf hingewiesen, daß der Zusatz von Bariumcarbonat eine hohe Schwindung verursacht und die Massen zur Blasenbildung neigen.Heuschkel-Muche: ABC Ceramics, 1975, pp. 23 and 166, describes the addition of barium carbonate as a flux. It should be noted that the addition of Barium carbonate causes a high shrinkage and the Masses tend to form bubbles.

Aus Silikattechnik, 1956, Seiten 329 und 330, sind sogenannte Schaumtone bekannt. Bei deren Herstellung nutzt man die Tatsache aus, daß die meisten flüssigen Tone bei etwa 1100°C zu schäumen beginnen. Als Blähhilfsmittel werden allenfalls Kalkstein, Dolomit oder eisenoxidreiche Stoffe zugesetzt. Silikattechnik, 1956, pages 329 and 330, are so-called Schaumtone known. In their production one uses the Fact that most liquid clays at about 1100 ° C to start foaming. Be used as a blowing aid possibly limestone, dolomite or iron oxide-rich substances added.  

Aus Silikattechnik, 1960, Seite 339, sind schließlich sogenannte Schaumanhydrite bekannt, die im Schaum- oder Gasverfahren hergestellt werden. Einzelheiten dieses Verfahrens werden jedoch dort nicht geschildert.From Silikattechnik, 1960, page 339, are finally so-called foam anhydrites known in the foam or Gas process can be produced. Details of this However, the procedure is not described there.

Aufgabe der Erfindung ist nunmehr, ein Verfahren zur Herstellung eines künstlichen Steins durch Mischen a) eines durch vorheriges Mischen von Tensiden, Bariumcarbonat und Wasser erzeugten Schaums, b) Ton, tonhaltigem Material, Keramik, Gips, Zement, Kalk oder einem Gemisch zweier oder mehrerer dieser Stoffe und c) Wasser, d) ggfs. Ausformen des so erhaltenen Gemischs, e) Trocknen und f) erforderlichenfalls Brennen der getrockneten Masse, zur Verfügung zu stellen, der die aufgezeigten Nachteile nicht hat und vielseitig verwendbar ist.The object of the invention is now a method for Production of an artificial stone by mixing a) a by prior mixing of surfactants, barium carbonate and Water produced foam, b) clay, clay-containing material, Ceramics, gypsum, cement, lime or a mixture of two or several of these substances and c) water, d) if necessary thus obtained mixture, e) drying and f) if necessary, burning of the dried mass, To make available, the disadvantages do not show has and is versatile.

Diese Aufgabe wird erfindungsgemäß dadurch gelöst, daß bezogen auf den vorgemischten Schaum gemäß Schritt a) der Anteil der Tenside 0,03 bis 0,5 Gew.-%, an Bariumcarbonat 0,01 bis 1 Gew.-% und an Wasser 98,5 bis 99,96 Gew.-% und bezogen auf das Gesamtgemisch der Anteil des Schaums gemäß Schritt a) 1,5 bis 8 Gew.-%, des Materials gemäß Schritt b) 30 bis 74 Gew.-% und des Wassers gemäß Schritt c) 68,5 bis 18 Gew.-% beträgt.This object is achieved in that based on the premixed foam according to step a) of Proportion of surfactants from 0.03 to 0.5% by weight of barium carbonate 0.01 to 1 wt .-% and water 98.5 to 99.96 wt .-% and based on the total mixture, the proportion of the foam according to Step a) 1.5 to 8 wt .-%, of the material according to step b) 30 to 74 wt .-% and the water according to step c) 68.5 to 18 wt .-% is.

Unter Tensiden werden vorliegend Aniontenside (z. B. Seifen, Alkansulfonate, Olefinsulfonate, Estersulfonate, Alkylarylsulfonate, Alkylsulfonate, Alkylsulfate, Ethersulfate, Fettalkoholsulfate), Kationtenside (z. B. geradkettige und cyclische Ammoniumverbindungen, Benzalkoniumchloride, quartäre Ammoniumsalze, Aminsalze, Pyridiniumsalze), nichtionogene Tenside (z. B. Polyether, Aminoxide, Fettsäureester von Polyalkoholen), Amphotenside (z. B. Glycinderivate mit Betain-Struktur, Sulfobetaine) verstanden. Erfindungsgemäß werden Aniontenside bevorzugt. Surfactants in the present case are anionic surfactants (for example soaps, Alkanesulfonates, olefin sulfonates, ester sulfonates, Alkylarylsulfonates, alkylsulfonates, alkylsulfates, Ether sulfates, fatty alcohol sulfates), cationic surfactants (e.g. straight-chain and cyclic ammonium compounds, Benzalkonium chlorides, quaternary ammonium salts, amine salts, Pyridinium salts), nonionic surfactants (eg polyethers, Amine oxides, fatty acid esters of polyalcohols), amphoteric surfactants (eg glycine derivatives with betaine structure, sulfobetaines) Roger that. In accordance with the invention, anionic surfactants are preferred.  

Als Tensid können Seifen im Gemisch mit den anderen oben genannten oberflächenaktiven Substanzen verwendet werden. Unter Seifen sind hierbei u. a. wasserlösliche Natrium- und Kaliumsalze der gesättigten und ungesättigten höheren Fettsäuren, der Harzsäuren des Kolophoniums und der Naphtensäuren zu verstehen. Ebenso können aber auch Metallseifen, d. h. Salze der genannten Säuren mit anderen Metallen, in Betracht kommen.As a surfactant, soaps can be mixed with the others above mentioned surface-active substances are used. Under soaps here u. a. water-soluble sodium and Potassium salts of saturated and unsaturated higher Fatty acids, rosin acids of rosin and To understand naphthenic acids. But you can as well Metal soaps, d. H. Salts of said acids with others Metals, come into consideration.

Die Komponente b) besteht aus den oben angeführten Substanzen. Zu den einsetzbaren Tonen gehören u. a. Begußton, Glasurton, Blähton, Steinzeugton, Steingutton, Bentonit, Hafenton, Kapselton, Ziegelton und Mergelton.Component b) consists of the above-mentioned Substances. The usable clays include u. a. Begußton, Glasurton, expanded clay, stoneware clay, earthenware clay, bentonite, Harbor tone, capsule tone, brick tone and merlon tone.

Unter Keramik werden hier anorganische, nichtmetallische Werkstoffe verstanden, die in der Regel Kristall- und Glasphase nebeneinander enthalten. Hierzu zählen u. a. Keramiken auf Silikatbasis (tonkeramische Wirkstoffe), z. B. Ziegel, Terrakotten, Schamotte, Tonsteine, Feuertonwaren. Ebenso sind in diesem Zusammenhang sonderkeramische Werkstoffe zu erwähnen, d. h. Silikatsteine, Forsteritsteine, Korundsteine, SiC-Steine. Ferner sind unter Keramik auch auf nichtsilikatischen (z. B. Al₂O₃, MgO, ZrO₂) und nichtoxidischen (z. B. Carbide, Nitride, Boride) Verbindungen basierende Stoffe zu verstehen. Eine erfindungsgemäß besonders geeignete Verbindung ist Bariumcarbonat.Under ceramics here are inorganic, non-metallic Materials understood, which are usually crystal and Glass phase next to each other. These include u. a. Silicate-based ceramics (clay-ceramic active substances), eg. B. Brick, terracotta, chamotte, clay stones, boning products. Similarly, in this context are special ceramic To mention materials, d. H. Silicate stones, forsterite stones, Corundum stones, SiC stones. Further, under ceramics are also on non-silicate (eg Al₂O₃, MgO, ZrO₂) and non-oxidic (eg carbides, nitrides, borides) compounds to understand based substances. An invention particularly suitable compound is barium carbonate.

Unter Gips werden vorliegend die Dihydrate (CaSO₄ · 2 H₂O), Halbhydrate (CaSO₄ · 1/2 H₂O) und die Anhydrite (CaSO₄) des Kalziumsulfats verstanden.Gypsum is the dihydrate in the present case (CaSO₄ · 2 H₂O), hemihydrates (CaSO₄ · 1/2 H₂O) and the anhydrites (CaSO₄) understood the calcium sulfate.

Als Zement kommen handelsüblicher Portlandzement, Eisenportlandzement, Hochofenzement und Traßzement in Betracht. Die chemische Zusammensetzung der vorzugsweise für die vorliegende Erfindung geeigneten Zemente kann der folgenden Tabelle entnommen werden: As cement come commercial Portland cement, Iron portland cement, blast furnace cement and Trazzement in Consideration. The chemical composition of preferably For the present invention suitable cements of the following table:  

Die Werte geben die in konzentrierter Salzsäure löslichen Bestandteile in Gew.-% an, bezogen auf den glühverlustfreien Zement. H=Höchstwert, M=Mittelwert, N=Niedrigstwert. The values give those soluble in concentrated hydrochloric acid Ingredients in wt .-% of, based on the Lossless cement. H = maximum value, M = average value, N = lowest value.  

Als Kalk kommen sämtliche handelsüblichen Sorten in Betracht, insbesondere Branntkalk (85 bis 95% CaO), Kohlensaurer Kalk (80 bis 95% CaCO₃), Hüttenkalk (47% CaO), Konverterkalk (45% CaO), Thomaskalk (46% CaO), Löschkalk (60 bis 70% CaO), Mischkalk (60 bis 65% CaO), Stückkalk (90% CaO). Ebenso kommen magnesiumhaltige Kalke zur Anwendung, z. B. Magnesium-Branntkalk (70 bis 80% CaO und 15% MgO).As lime come all commercial varieties in Consideration, in particular burnt lime (85 to 95% CaO), Carbonic lime (80 to 95% CaCO₃), lime (47% CaO), converter lime (45% CaO), thomalcalk (46% CaO), Slaked lime (60 to 70% CaO), mixed lime (60 to 65% CaO), Lump lime (90% CaO). Likewise come magnesium-containing limestones for use, eg. As magnesium quicklime (70 to 80% CaO and 15% MgO).

Als Schaumbaustoffe für gebrannte Steine werden vor allem Schaumton und Schaumkeramik bevorzugt. Gemische aus Schaumkeramik, Schaumton, Schaumgips, Schaumzement und Schaumkalk weisen ein geringes Gewicht im Vergleich zu den gelochten Ausführungen nach dem Stand der Technik auf. Als Zusatzstoffe können Titandioxid, Bentonit, tonhaltiges Material und Mineralfasern vorhanden sein. Durch Glasuren und/oder andere Imprägnierungsmittel, z. B. Kunststoffe und Reaktionsharze, kann eine Erhöhung der Festigkeit erreicht werden.As foam building materials for fired stones are mainly Foam clay and foam ceramic preferred. Mixtures off Schaumkeramik, foam clay, foam, foam cement and Lime is low in weight Compared to the perforated versions according to the state of Technology on. As additives titanium dioxide, Bentonite, clay-containing material and Mineral fibers are present. Through glazes and / or other impregnating agents, e.g. B. plastics and Reaction resins, an increase in strength can be achieved become.

Die nach dem erfindungsgemäßen Verfahren hergestellten Steine sind aufgrund ihres geringen Gewichts für die Erstellung von Bauelementen der verschiedensten Art geeignet. Sie sind insbesondere auch für Möbelteile verwendbar. Das Material ist beständig gegen Hitze und Feuer, gegen Kälte, UV-Strahlen und sonstige Witterungseinflüsse. Ebenso zeichnet sich das erfindungsgemäße gebrannte Material besonders durch seine Beständigkeit gegen Frost und verschiedene Chemikalien aus. The produced by the process according to the invention Stones are for the sake of their light weight Creation of components of various kinds suitable. They are especially for furniture parts usable. The material is resistant to heat and Fire, against cold, UV rays and others Weather. The same is true Burned material according to the invention especially by his Resistant to frost and various chemicals.  

Die nach dem erfindungsgemäßen Verfahren hergestellten Steine eignen sich auch als Leichtbausteine. Diese weisen nicht die Nachteile der bisher bekannten Leichtbausteine auf und ermöglichen eine Anwendung in vielen Bereichen. Sie können für belastetes und unbelastetes Mauerwerk verwendet werden und bieten eine entsprechend hohe Wärmedämmung. Das Material ist leicht zu sägen und zu transportieren. Die nach dem erfindungsgemäßen Verfahren hergestellten Steine unterscheiden sich von herkömmlichen Leichtbaustoffen auch durch ihre Schaumstruktur.The produced by the process according to the invention Stones are also suitable as lightweight building blocks. These wise not the disadvantages of the previously known lightweight components and allow an application in many areas. you can be used for loaded and unloaded masonry be and offer a correspondingly high thermal insulation. The material is easy to saw and transport. The stones produced by the process according to the invention also differ from conventional lightweight construction materials through their foam structure.

Aufgrund des geringen Gewichts und der Stabilität sowie der Feuer- und Frostbeständigkeit sind die nach dem erfindungsgemäßen Verfahren hergestellten Steine auch besonders für die Erstellung von Filteranlagen in Innen- und Außenräumen geeignet. Die Tatsache, daß das Material UV-strahlenbeständig ist, ermöglicht seine Anwendbarkeit mit einer langen wartungsfreien Lebensdauer. Insbesondere für Anlagen mit geringen Belastungsmöglichkeiten bieten die Steine aufgrund des geringen Gewichts neue Gestaltungsmöglichkeiten. Die einzelnen Steine können hierbei mit verschiedenen handelsüblichen Bindemitteln zusammengefügt werden.Due to the low weight and the stability as well as the Fire and frost resistance are the after stones produced according to the invention also especially for the creation of filter systems in indoor and outdoor Outdoor spaces suitable. The fact that the material UV radiation resistant, allows its applicability with a long maintenance-free life. Especially for Systems with low load options offer the New stones due to the low weight Design options. The individual stones can in this case with various commercially available binders be joined together.

Die Verwendung der nach dem erfindungsgemäßen Verfahren hergestellten künstlichen Steine liegt vor allem im Bausektor. Beispielsweise sind die Steine als Bausteine, Bauplatten und Isolierfassadenplatten einsetzbar. Ebenso ist das Material für Natursteinimitationen geeignet. Ein weiteres Anwendungsgebiet sind der Bau von Feuerschutzelementen, Brunnenanlagen, Öfen, Filteranlagen, Biotopen, Riffbau, Füllstoffen und Granulaten sowie die Erstellung von künstlichen Knochen und Gelenken sowie die Kieferchirurgie. The use of the method according to the invention produced artificial stones is mainly in the Construction sector. For example, the stones are as building blocks, Building boards and insulated facade panels used. Likewise is the material suitable for natural stone imitations. On Another area of application is the construction of Fire protection elements, well systems, ovens, filter systems, Biotopes, reef building, fillers and granules and the Creation of artificial bones and joints as well as the Oral surgery.  

Schließlich können die erfindungsgemäßen Steine als Trägermaterial oder Füllmaterial in Reaktoren, insbesondere Festbettreaktoren eingesetzt werden. Das Trägermaterial ist vor allem für die Immobilisierung von Biokatalysatoren geeignet. Beispiele für solche Biokatalysatoren sind Enzyme, pflanzliche oder tierische Zellen sowie Mikroorganismen. Immobilisierungen mit den erfindungsgemäßen Steinen kommen bei den verschiedensten Bioverfahren, insbesondere aber in der Abwasserreinigung in Betracht.Finally, the stones of the invention as Support material or filler in reactors, in particular Fixed bed reactors are used. The carrier material is especially for the immobilization of biocatalysts suitable. Examples of such biocatalysts are enzymes, plant or animal cells and microorganisms. Immobilisations come with the stones of the invention in a variety of bioprocessing, but especially in the wastewater treatment into consideration.

Besonders gute Ergebnisse lassen sich erzielen, wenn der Anteil des Materials gemäß Schritt b) annähernd dem des Wassers gemäß Schritt c) entspricht. Die Gewichtsprozente liegen in diesem Fall bei 1,5 bis 2,5 (Schritt a)), 30 bis 68,5 (Schritt b)) und 68,5 bis 29 (Schritt c)).Particularly good results can be achieved if the Proportion of the material according to step b) approximately that of Water according to step c) corresponds. The weight percentages in this case are 1.5 to 2.5 (step a)), 30 to 68.5 (step b)) and 68.5 to 29 (step c)).

Hervorzuheben ist, daß durch Verwendung von Bariumcarbonat oder eines Gemisches von Titandioxid und Bariumcarbonat oder eines Gemisches von Titandioxid und Bentonit in Schritt b) sich besonders gute Ergebnisse erzielen lassen. Daneben werden die in den folgenden Beispielen genannten Gemische für Schritt b) bevorzugt:It should be emphasized that by using barium carbonate or a mixture of titanium dioxide and barium carbonate or a mixture of titanium dioxide and bentonite in step b) to achieve particularly good results. Besides are the mixtures mentioned in the following examples for step b) preferred:

1. Zusammenstellung Gemische (Anteile in %)1. Composition of mixtures (shares in%) Quarzmehl|62,5%Silica flour | 62.5% Stuckgipsstucco 12,5%12.5% Glasur Transp.Glaze Transp. 12,5%12.5% Glasfaser 1 mmGlass fiber 1 mm 12,5%12.5%

2. Zusammenstellung2. Compilation Quarzmehlsilica flour 5555 Stuckgipsstucco 1212 Glasurglaze 2222 Weißtonwhiteness 1111

3. Zusammenstellung3. Compilation Quarzmehlsilica flour 6767 Stuckgipsstucco 1717 Weißtonwhiteness 1616

4. Zusammenstellung4. Compilation Quarzmehlsilica flour 8080 Glasur Transp.Glaze Transp. 2020

5. Zusammenstellung5. Compilation Quarzmehlsilica flour 58,858.8 TitandioxidTitanium dioxide 5,85.8 Weißtonwhiteness 11,811.8 Glasfaser 1 mm @Glass fiber 1 mm @ Glasurglaze 11,811.8 Gipsplaster 11,811.8

6. Zusammenstellung6. Compilation Glasfaserglass fiber 2525 Tonvolume 2525 Glasur BleiGlaze lead 2525 Gipsplaster 2525

7. Zusammenstellung7. Compilation Gipsplaster 5050 Glasfaser 1 mmGlass fiber 1 mm 5050

8. Zusammenstellung8. Compilation Stuckgipsstucco 4040 Glasfaser 1 mmGlass fiber 1 mm 4040 TitandioxidTitanium dioxide 2020

9. Zusammenstellung9. Compilation Kaolinkaolin 7171 Gipsplaster 1414 Glasurglaze 1515

10. Zusammenstellung10. Compilation Schamottefire clay 6060 Zementcement 2020 Glasurglaze 2020

11. Zusammenstellung11. Compilation Zementcement 8080 Glasurglaze 2020

12. Zusammenstellung12. Compilation Zementcement 2020 Quarzmehlsilica flour 4040 Schamottefire clay 4040

13. Zusammenstellung13. Compilation TitandioxidTitanium dioxide 9090 Bentonitebentonite 1010

14. Zusammenstellung14. Compilation Gipsplaster 5050 Glasurglaze 5050

15. Zusammenstellung15. Compilation Quarzmehlsilica flour 7070 Stuckgipsstucco 1515 Glasurglaze 1515

16. Zusammenstellung16. Compilation Quarzmehlsilica flour 2525 Stuckgipsstucco 2525 Glasfaser 1 mmGlass fiber 1 mm 2525 Schamotte WeißtonChamotte white tone 2525

17. Zusammenstellung17. Compilation Gipsplaster 7070 Bariumcarbonatbarium carbonate 3030

18. Zusammenstellung18. Compilation Cobaltoxidcobalt oxide 5050 Weißtonwhiteness 5050

19. Zusammenstellung19. Compilation Kreidechalk 62,562.5 Gipsplaster 12,512.5 Glasurglaze 2525

20. Zusammenstellung20. Compilation Quarzmehlsilica flour 6060 Kalklime 2020 Glasur Transp.Glaze Transp. 2020

21. Zusammenstellung21. Compilation Quarzmehlsilica flour 6060 Kalklime 4040

22. Zusammenstellung22. Compilation Keramische FasernCeramic fibers 7070 Tonvolume 3030

23. Zusammenstellung23. Compilation Gipsplaster 3030 Oxidenoxides 7070

24. Zusammenstellung24. Compilation Zementcement 3030 Oxidenoxides 7070

25. Zusammenstellung25. Compilation Oxidenoxides 8080 Ton (Weißton)Sound (white tone) 2020

Durch verschiedene Zusatzstoffe kann die chemische Affinität zwischen den einzelnen Komponenten erhöht werden. Beispiele hierfür sind Bentonite, Titandioxid und Bariumcarbonat, sofern diese Stoffe nicht bereits in Schritt b) zugegeben wurden. Die Festigkeit kann durch Zusatzstoffe ebenfalls erhöht werden, insbesondere durch Tränkung in verschiedenen Glasuren und/oder Imprägnierungsmitteln, wie Kunststoffen, Reaktionsharzen, flüssigem Gas und Mineralstoffen. Die Zugabe von Gips hat zur Folge, daß sich schon nach etwa einer halben Stunde das Gemisch versteift.Through various additives, the chemical affinity be increased between the individual components. Examples these are bentonites, titanium dioxide and barium carbonate, unless these substances have already been added in step b) were. The firmness can by additives likewise be increased, in particular by impregnation in different Glazes and / or impregnating agents, such as plastics, Reaction resins, liquid gas and minerals. The Addition of gypsum has the consequence that after about stiffened the mixture for half an hour.

Im Gegensatz zum bisherigen Stand der Technik wird zunächst ein Schaum durch Mischen von Tensiden, Bariumcarbonat und Wasser hergestellt. Vorzugsweise werden hier 0,03 bis 0,5 Gew.-% Tensid, 0,01 bis 1 Gew.-% Bariumcarbonat und 98,5 bis 99,96 Gew.-% Wasser, bezogen auf 100% Schaum, verwendet.In contrast to the prior art, first a foam by mixing surfactants, barium carbonate and Water produced. Preferably, 0.03 to 0.5 wt .-% here Surfactant, 0.01 to 1 wt .-% barium carbonate and 98.5 to 99.96% by weight of water, based on 100% foam, used.

Durch das Vorhandensein von Bariumcarbonat in Seifen und Tensiden läßt sich bereits bei leichtem Rühren eine stabile Schaumstruktur erreichen, die bei alleiniger Anwendung von Seifen und/oder Tensiden schneller verfällt und bei der Trocknung nicht erhalten bleibt. An das kolloide Bariumcarbonat lagern sich die Stoffe der Komponenten b an. Hierdurch ist es möglich, mit den verschiedenartigsten Rohstoffen Schaumbaustoffe zu erzeugen. Insbesondere sind die als Komponenten b bezeichneten Substanzen und deren Gemische für die vorliegende Erfindung geeignet. Außerdem läßt sich bei Einsatz von Bariumcarbonat die Menge an schaumbildenden, d. h. ausbrennbaren Stoffen reduzieren. Insbesondere sind nur noch geringe Mengen an Tensiden nötig. Ferner wird durch den erfindungsgemäßen Zusatz von Bariumcarbonat das sogenannte "Ausblühen" verhindert, d. h. die vorhandenen löslichen Salze (Chloride, Sulfate) werden in unlösliches Bariumsulfat überführt. Schließlich dient Bariumcarbonat als Flußmittel. Hierbei lassen sich matte oder glänzende Produkte erzeugen.Due to the presence of barium carbonate in soaps and surfactants, a stable foam structure can be achieved even with gentle stirring, which lapses faster when used alone with soaps and / or surfactants and is not retained during drying. The substances of components b are deposited on the colloidal barium carbonate. This makes it possible to produce foam materials with a wide variety of raw materials. In particular, the substances designated as components b and mixtures thereof are suitable for the present invention. In addition, when barium carbonate is used, the amount of foaming, ie burnable, substances can be reduced. In particular, only small amounts of surfactants are needed. Furthermore, the addition of barium carbonate according to the invention prevents so-called "blooming", ie the soluble salts present (chlorides, sulfates) are converted into insoluble barium sulfate. Finally, barium carbonate serves as a flux. This can produce dull or shiny products.

Die aufgeschäumte Emulsion bildet eine glatte Schalenstruktur, die durch Zusatz verschiedener Stoffe beliebig gehärtet oder auch poröser gemacht werden kann und beim Ofenbrand ausgebrannt wird. Die ausbrennbaren Bestandteile sind sehr viel geringer als bisher bekannt und hinterlassen keine Rückstände. Die Emulsionen sind daher schwer entflammbar, raumsparend, umweltfreundlich und feuchtigkeitsunempfindlich.The foamed emulsion forms a smooth Shell structure created by adding different substances can be hardened arbitrarily or made more porous and burned out during kiln firing. The burnable Ingredients are much lower than previously known and leave no residue. The emulsions are therefore flame retardant, space saving, environmentally friendly and insensitive to moisture.

Erst nachdem der Schaum hergestellt worden ist, wird dieser mit Wasser und Ton, Keramik, Gips, Zement oder Kalk oder Gemischen dieser Stoffe vermischt. Durch das spezielle Herstellungsverfahren wird ein geschäumter Stein in besonders einfacher Weise erzeugt; denn die Schaumbildung ist nicht von bei einer bestimmten Temperatur schäumenden Tonen abhängig. Das heißt, eingesetzte Materialien und Temperaturen lassen sich in weiten Grenzen variieren. Wesentlich für die Bildung der Schaumstruktur ist nur das Vorhandensein der angegebenen Minimalmenge an Bariumcarbonat und Tensid, wobei bemerkenswert ist, daß die eingesetzten Mengen wesentlich geringer sind als bei der bisher bekannten alleinigen Verwendung von Seife. Eine variierte Schaumstruktur läßt sich durch Zusatz an sich bekannter Füllstoffe erreichen. Beispiele hierfür sind Polystyrol und Blähtone (Korund). Insbesondere lassen sich auf diese Weise Gitterstrukturen erreichen.Only after the foam has been made, this is with water and clay, ceramics, plaster, cement or lime or mixtures of these Substances mixed. Due to the special manufacturing process becomes a foamed stone in a particularly simple way generated; because the foaming is not by at one depending on the temperature of foaming clays. This means, used materials and temperatures can be in wide limits vary. Essential for the formation of the Foam structure is just the presence of specified Minimum amount of barium carbonate and surfactant, wherein it is noteworthy that the quantities used are essential are lower than in the previously known sole Use of soap. Leaves a varied foam structure reach by addition of known fillers. Examples are polystyrene and expanded clay (corundum). In particular, lattice structures can be achieved in this way to reach.

Das Trocknen wird vorzugsweise im Heißluftstrom durchgeführt. Die Brenntemperaturen liegen vorzugsweise zwischen 900 und 1700°C.The drying is preferably in the hot air stream carried out. The firing temperatures are preferably between 900 and 1700 ° C.

Claims (3)

1. Verfahren zur Herstellung eines künstlichen Steins durch Mischen
  • a) eines durch vorheriges Mischen von Tensiden, Bariumcarbonat und Wasser erzeugten Schaums,
  • b) Ton, tonhaltigem Material, Keramik, Gips, Zement, Kalk oder einem Gemisch zweier oder mehrerer dieser Stoffe und
  • c) Wasser,
  • d) ggfs. Ausformen des so erhaltenen Gemischs,
  • e) Trocknen und
  • f) erforderlichenfalls Brennen der getrockneten Masse nach Patentanmeldung 38 04 884.1,
1. A method for producing an artificial stone by mixing
  • a) a foam produced by previously mixing surfactants, barium carbonate and water,
  • (b) clay, clayey material, ceramics, gypsum, cement, lime or a mixture of two or more of these substances and
  • c) water,
  • d) optionally shaping the mixture thus obtained,
  • e) drying and
  • f) if necessary, firing the dried mass according to patent application 38 04 884.1,
dadurch gekennzeichnet, daß bezogen auf den vorgemischten Schaum gemäß Schritt a) der Anteil der Tenside 0,03 bis 0,5 Gew.-%, an Bariumcarbonat 0,01 bis 1 Gew.-% und an Wasser 98,5 bis 99,96 Gew.-% und bezogen auf das Gesamtgemisch der Anteil des Schaums gemäß Schritt a) 1,5 bis 8 Gew.-%, des Materials gemäß Schritt b) 30 bis 74 Gew.-% und des Wassers gemäß Schritt c) 68,5 bis 18 Gew.-% beträgt. characterized in that based on the premixed foam according to step a), the proportion of surfactants from 0.03 to 0.5 wt .-% of barium carbonate 0.01 to 1 wt .-% and water 98.5 to 99.96 Wt .-% and based on the total mixture, the proportion of the foam according to step a) 1.5 to 8 wt .-%, the material according to step b) 30 to 74 wt .-% and the water according to step c) 68.5 to 18 wt .-% is. 2. Verfahren gemäß Anspruch 1, dadurch gekennzeichnet, daß der Anteil des Schaums gemäß Schritt a) 1,5 bis 7 Gew.-%, des Materials gemäß Schritt b) 48,5 bis 74 Gew.-% und des Wassers gemäß Schritt c) 50 bis 19 Gew.-% beträgt.2. Method according to claim 1, characterized in that the Proportion of the foam according to step a) 1.5 to 7 wt .-%, of Material according to step b) 48.5 to 74 wt .-% and of Water according to step c) is 50 to 19 wt .-%.
DE3835851A 1988-02-17 1988-10-21 Method of manufacturing artificial stones Expired - Lifetime DE3835851C1 (en)

Priority Applications (4)

Application Number Priority Date Filing Date Title
DE3835851A DE3835851C1 (en) 1988-02-17 1988-10-21 Method of manufacturing artificial stones
EP89119483A EP0365022B1 (en) 1988-10-21 1989-10-20 Process for the production of artificial stones
DE89119483T DE58905965D1 (en) 1988-10-21 1989-10-20 Process for the production of artificial stones.
AT89119483T ATE96138T1 (en) 1988-10-21 1989-10-20 PROCESS FOR MAKING ARTIFICIAL STONES.

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE19883804884 DE3804884A1 (en) 1987-04-24 1988-02-17 Synthetic bricks and process for the production of the same
DE3835851A DE3835851C1 (en) 1988-02-17 1988-10-21 Method of manufacturing artificial stones

Publications (1)

Publication Number Publication Date
DE3835851C1 true DE3835851C1 (en) 1990-05-31

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Non-Patent Citations (2)

* Cited by examiner, † Cited by third party
Title
HEUSCHKEL - MUCHE: ABC Keramik, 1975, S. 23, 166 *
PROBST: Handbuch der Betonsteinindustrie, 1962, S. 12 *

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