Decorative construction material and methods of its production
First Claim
Patent Images
1. A method of producing a two layer construction material, comprising the steps of:
- (a) mixing together at least one material selected from the group consisting of sand, slag granulate and crushed glass granulate, and mixtures thereof, together with a bonding agent and aluminum oxide and forming a first layer in a mold;
(b) disposing on the first layer a second layer comprising glass granulate such that the second layer is positioned directly upon the first layer; and
(c) thermally treating the first and second layers in the mold such that the temperature during thermal treatment is sufficient to sinter the first and second layers to form a construction material having only two layers.
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Abstract
A decorative construction material such as a glass tile is produced from recycled glass granulate, and exhibits a smooth, external surface substantially free from defects on one side of the tile. One or two layer tiles may be produced. A binder, together with control of the maximum temperature and temperature gradient in the layers, if applicable, is used during manufacture to ensure a substantially flawless outer surface.
31 Citations
23 Claims
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1. A method of producing a two layer construction material, comprising the steps of:
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(a) mixing together at least one material selected from the group consisting of sand, slag granulate and crushed glass granulate, and mixtures thereof, together with a bonding agent and aluminum oxide and forming a first layer in a mold; (b) disposing on the first layer a second layer comprising glass granulate such that the second layer is positioned directly upon the first layer; and (c) thermally treating the first and second layers in the mold such that the temperature during thermal treatment is sufficient to sinter the first and second layers to form a construction material having only two layers. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18)
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19. A method of producing a two layer construction material, comprising the steps of:
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(a) placing a first layer comprising at least one material selected from the group comprising sand, slag and granulated glass, and mixtures thereof, together with sodium silicate and aluminum oxide into a mold; (b) compacting and leveling the first layer in the mold; (c) disposing a second layer comprising granulated glass on the first layer, such that the second layer is in direct contact with the first layer; (d) compacting and leveling the second layer; (e) heating the mold and first and second layers to a temperature sufficient to sinter the first and second layers; (f) maintaining the temperature for a period of time sufficient to assure that the layers maintain an adequate strength without cracking; and (g) cooling and annealing the resulting two layer construction material. - View Dependent Claims (20, 21)
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22. A method of producing a two layer construction material, comprising the steps of:
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(a) placing a first layer comprising at least one material selected from the group consisting of sand, slag, and granulated glass, and mixtures thereof, together with sodium silicate and aluminum oxide and an easily combustible material into a mold; (b) compacting the first layer in the mold; (c) heating the first layer to the combustion temperature of the easily combustible material; (d) maintaining the combustion temperature until gas formation within the first layer is complete; (e) cooling the first layer; (f) disposing a second layer comprising granulated glass on the first layer, such that the second layer is in direct contact with the first layer; (g) compacting and leveling the second layer; (h) heating the mold and first and second layers to a temperature sufficient to sinter the first and second layers; (i) maintaining the temperature for a period of time sufficient to assure that the layers maintain an adequate strength without cracking; and (j) cooling and annealing the resulting two layer construction material. - View Dependent Claims (23)
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Specification