Process for the manufacturing of slabs or blocks of conglomerate of stone granulate and polyester resin

Abstract

In the manufacture of articles in slabs or blocks according to so-called Bretonstone technology, a polyester resin is employed, free of reactive solvents, formed by the reaction between an epoxidised triglyceride and at least one carboxylic anhydride.

What is claimed is: 
     
         1 . A method of manufacturing an article in a form of one of slabs and blocks,
 the article comprising
 an initial mixture of any stone or stone-like granulate material and a hardenable binder resin, stone or stone-like granulate material comprising a selected granulometry; 
 the binder resin comprising a polyester resin, the polyester resin lacking a reactive solvent, the polyester resin being formed by reaction between at least one epoxidised triglyceride and at least one carboxylic anhydride; 
 the mixture having a vacuum-compressed and vibratory-motion dense structure; 
   the method comprising the steps of:
 (a) preparing the initial mixture; 
 (b) depositing the initial mixture on one of a temporary support or a mould as a deposited mixture, the one of a temporary support and mould comprising dimensions of the article; 
 (c) vacuum compressing the deposited mixture while accompanying application of vibratory motion at a pre-established frequency to form the vacuum-compressed and vibratory-motion dense structure; and 
 (d) hardening the binder resin at a temperature ranging from 80 to 180 degrees Centigrade to form the article; 
   wherein step (a) is performed by mixing the stone or the stone-like granulate material and the polyester resin forming components comprising the at least one epoxidised triglyceride and the at least one carboxylic anhydride.   
     
     
         2 . The method of  claim 1 , wherein the at least one carboxylic anhydride is selected from one of a methyl-tetrahydrophthalic anhydride, a tetrahydrophthalic anhydride, or a mixture of a methyltetrahydrophthalic anhydride and a tetrahydrophthalic anhydride. 
     
     
         3 . The method of  claim 1 , wherein the at least one carboxylic anhydride is selected from tetrahydro-4-methylphthalic anhydride; 1,2,3,6-tetrahydro-3-methylphthalic anhydride; 1,2,3,6-tetrahydrophthalic anhydride; and mixtures thereof. 
     
     
         4 . The method of  claim 1 , wherein the at least one epoxidised triglyceride is selected from among triglycerides of unsaturated fatty acids, mono- or poly-unsaturated that are liquid at room temperature. 
     
     
         5 . The method of  claim 2 , wherein the at least one epoxidised triglyceride is selected from among triglycerides of unsaturated fatty acids, mono- or poly-unsaturated that are liquid at room temperature. 
     
     
         6 . The method of  claim 3 , wherein the at least one epoxidised triglyceride is selected from among triglycerides of unsaturated fatty acids, mono- or poly-unsaturated that are liquid at room temperature. 
     
     
         7 . The method of  claim 1 , wherein the initial mixture comprises a catalyst initiator. 
     
     
         8 . The method of  claim 2 , wherein the initial mixture comprises a catalyst initiator. 
     
     
         9 . The method of  claim 3 , wherein the initial mixture comprises a catalyst initiator. 
     
     
         10 . The method of  claim 7 , wherein the catalyst initiator is selected from among halides of alkaline metals, organometallic compounds of aluminum, zinc and tin, halides of quaternary ammonium, aliphatic and aromatic amines, boron and titanium based complexes. 
     
     
         11 . The method of  claim 8 , wherein the catalyst initiator is selected from among halides of alkaline metals, organometallic compounds of aluminum, zinc and tin, halides of quaternary ammonium, aliphatic and aromatic amines, boron and titanium based complexes. 
     
     
         12 . The method of  claim 9 , wherein the catalyst initiator is selected from among halides of alkaline metals, organometallic compounds of aluminum, zinc and tin, halides of quaternary ammonium, aliphatic and aromatic amines, boron and titanium based complexes. 
     
     
         13 . The method of  claim 9 , wherein the catalyst initiator is selected from among halides of alkaline metals, organometallic compounds of aluminum, zinc and tin, halides of quaternary ammonium, aliphatic and aromatic amines, boron and titanium based complexes. 
     
     
         14 . The method of  claim 1 , wherein the reaction of formation of polyester resin and hardening takes place at a temperature of 140° C. 
     
     
         15 . An article in the form of a slab or block, the article comprising:
 a mixture of any stone or stone-like granulate material and a hardenable binder resin, stone or stone-like granulate material comprising a selected granulometry;   the binder resin comprising a polyester resin, the polyester resin lacking a reactive solvent, the polyester resin being formed by reaction between at least one epoxidised triglyceride and at least one carboxylic anhydride;   the mixture having a vacuum-compressed and vibratory-motion dense structure.   
     
     
         16 . The article of  claim 15 , wherein the at least one carboxylic anhydride is selected from one of a methyl-tetrahydropthtalic anhydride, a tetrahydropthtalic anhydride, or a mixture of a methyltetrahydropthtalic anhydride and a tetrahydropthtalic anhydride. 
     
     
         17 . The article of  claim 15 , wherein the at least one carboxylic anhydride is selected from tetrahydro-4-methylphthalic anhydride; 1,2,3,6-tetrahydro-3-methylphthalic anhydride; 1,2,3,6-tetrahydrophthalic  anhydride; and mixtures thereof. 
     
     
         18 . The article of  claim 15 , wherein the epoxidised triglyceride is selected from among triglycerides of unsaturated fatty acids, mono- or poly-unsaturated which are liquid at room temperature. 
     
     
         19 . The article of  claim 15 , wherein the anhydride is selected from among pyromellitic anhydride, maleic anhydride, succinic anhydride, hexahydrophthalic anhydride, phthalic anhydride, anhydride of norbornene dicarboxylic acid, adipic anhydride, glutaric anhydride, methylphthalic anhydride, 1, 2-cyclohexyldicarboxylic anhydride, 3-methyl-1, 2-cyclohexyldicarboxylic anhydride, 4-methyl-1, 2-cyclohexyldicarboxylic anhydride, mixture of 3-methyl-1, 2-cyclohexyldicarboxylic and 4-methyl-1, 2-cyclohexyldicarboxylic anhydrides, methyl-tetrahydrophthalic anhydride, tetrahydrophthalic anhydride, methyl-5-norbornen-2, 3-dicarboxylic anhydride, dodecenyl-succinic anhydride and mixtures of the same. 
     
     
         20 . The article of  claim 15 , wherein the mixture comprises a catalyst initiator. 
     
     
         21 . The article of  claim 20 , wherein the catalyst initiator is selected from among halides of alkaline metals, organometallic compounds of aluminum, zinc and tin, halides of quaternary ammonium, aliphatic and aromatic amines, boron and titanium based complexes.