PROCESS FOR THE MANUFACTURE OF GLASS-CONTAINING SLABS AND PANELS OF AGGLOMERATED STONE AND GLASS/GLASS-CERAMIC MATRIX COMPOSITE MATERIALS

Abstract

The process of the invention presents a simple, effective and continuous process for producing slabs and panels from compositions free from ceramic components or ceramic binders.

Claims

1. A dry solid mixture composition of matter comprising a bulk matrix consisting of one or more granulates, and at least one binding material comprising glass and having a working point temperature according to ASTM below 1200 C.

2. The mixture according to claim 1, wherein said one or more granulates include at least one natural material selected from quartz, granite, porphyry, syenite, basalt, sandstone and sand.

3-5. (canceled)

6. The mixture according to claim 1, wherein the working point temperature is between 450 and 900 C.

7-9. (canceled)

10. The mixture according to claim 1, wherein said glass is in a form of at least one of glass powder and glass frits.

11. The mixture according to claim 1, further comprising a reinforcing material selected from high-melting transparent inorganic materials.

12. (canceled)

13. The mixture according claim 1, wherein the mixture is compacted to a form a green-body.

14. The mixture according to claim 1, wherein said binding material binds said bulk matrix to form an agglomerated stone material.

15-21. (canceled)

22. A process for manufacturing an agglomerated stone material, the process comprising: preparing a mixture comprising a binding phase comprising powders of glass and a bulk matrix of granulates having particles of maximum size consistent with a thickness of a final compacted agglomerated stone material; and sintering the mixture at a temperature of between 450 C. and 900 C. to obtain the agglomerated stone material.

23-24. (canceled)

25. The process according to claim 22c, wherein said compacting includes applying a pressure of at least 0.5 kg/sq. cm.

26. (canceled)

27. The process according to claim 22, wherein said agglomerated stone material is characterized by a water absorption of less than 0.01%.

28.-30. (canceled)

31. The dry solid mixture composition of claim 1, wherein an averaged grain size of said bulk matrix is between 1 to 7 mm.

32. The dry solid mixture composition of claim 1, wherein said working point temperature according to ASTM is below 900 C.

33. The process of claim 22, further comprising forming said mixture into a plate or slab.

34. The process of claim 22, further comprising: compacting the mixture prior to said sintering.

35. The process of claim 34, wherein said compacting is onto a molding support, the process further comprising: molding said mixture into a form of a plate prior to said sintering.

36. The mixture of claim 1, further comprising: an additive selected for at least one property from the group consisting of plasticizing the mixture, stabilizing the mixture, remaining solid at the working point temperature, undergoing a phase change at the working point temperature, undergoing a reaction with at least one other component in the mixture during processing, and undergoing decomposition or degradation, thereby leaving behind a vacancy or pore in the mixture.

37. The mixture of claim 11, further comprising a reinforcing material that remains solid at the working point temperature.

38. The mixture of claim 11, wherein said reinforcing material includes an organic fiber.

39. The mixture of claim 11, wherein said reinforcing material is transparent.

40. The process of claim 22, further comprising: spray drying prior to said sintering.

Description

DETAILED DESCRIPTION OF EMBODIMENTS

[0084] The following are non-limiting examples of certain embodiments of the present invention.

EXAMPLE 1

[0085] Mixture for the production of slabs,processing temperatures between 750 and 930 C.:

TABLE-US-00001 Glass (glaze compositions) 35% Sand (grain 0.4-0.8 mm) 45% Sand (grain 0.1-0.3 mm) 15% Fiber (Reinforcing additive) 2% Technological additives 3%

EXAMPLE 2

[0086] Mixture for the production of slabs, processing temperatures between 600 and 750 C.:

TABLE-US-00002 Glass (low-melting glass compositions) 30% Aggregate (grain 2.5-5 mm) 15% Aggregate (grain 1.5-2.5 mm) 15% Aggregate (grain 1-1.5 mm) 10% Aggregate (grain 0.4-0.8 mm) 10% Aggregate (grain 0.1-0.3 mm) 15% Fiber (Reinforcing additive) 2% Technological additives 3%

EXAMPLE 3

[0087] The mixture of Example 1 above was utilized in the manufacture of a slab, without mechanical treatment of the slab upper surface for the purpose of decorating this surface for a final product.

EXAMPLE 4

[0088] The mixture of Example 2 above was utilized in the manufacture of a slab. which was further dressed and polished. This product was characterized with a high aesthetical properties, e.g., having better optical characteristics.